Adjustable expansion cone assembly

ABSTRACT

An apparatus and method for radially expanding a tubular member. The apparatus includes a tubular support member, an adjustable expansion cone assembly coupled to the tubular support member and means for adjusting the expansion cone assembly.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a National Stage filing of PCT patent applicationSer. No. PCT/US02/25608, filed on Aug. 13, 2002, which claimed thebenefit of the filing date of U.S. provisional patent application Ser.No. 60/318,021, filed on Sep. 7, 2001, the disclosure of which isincorporated herein by reference.

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No. 09/440,338, filed on Nov. 15,1999, which claims priority from provisional application 60/108,558,filed on Nov. 16, 1998, (121) U.S. Pat. No. 7,055,608, which was filedas U.S. utility patent application Ser. No. 10/418,688, filed on Apr.18, 2003, as a division of U.S. Pat. No. 6,640,903, which was filed asU.S. utility patent application Ser. No. 09/523,468, filed on Mar. 10,2000, which claims priority from provisional application 60/124,042,filed on Mar. 11, 1999, and (122) U.S. utility patent application Ser.No. 10/784,679, filed on Feb. 23, 2004, which was a continuation-in-partof U.S. utility patent application Ser. No. 10/089,419, filed on Mar.27, 2002, which issued as U.S. Pat. No. 6,695,012, the disclosures ofwhich are incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to wellbore casings, and in particularto wellbore casings that are formed using expandable tubing.

Conventionally, when a wellbore is created, a number of casings areinstalled in the borehole to prevent collapse of the borehole wall andto prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

The present invention is directed to overcoming one or more of thelimitations of the existing procedures for forming new sections ofcasing in a wellbore.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage, a first lug coupled to and extending from thefirst tubular support body in the radial direction, a second lug coupledto and extending from the first tubular support body in the radialdirection, and an expansion cone support body coupled to the firsttubular support body. The expansion cone support body includes anN-sided tapered tubular support member, wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot. Nexpansion cone segments are movably coupled to the expansion conesupport body, each including an expansion cone segment body includingarcuate conical outer surfaces, a first T-shaped retaining membercoupled to the expansion cone segment body for movably coupling theexpansion cone segment body to a corresponding one of the T-shaped slotsof the expansion cone support body, and a second T-shaped retainingmember coupled to the expansion cone segment body. A split ring collarassembly is movably coupled to the exterior of the tubular supportmember that includes a second tubular support body defining N T-shapedslots for movably receiving corresponding ones of the second T-shapedretaining members of the expansion cone segments, and an L-shapedretaining member coupled to the second tubular support body. A firstdrag block assembly is movably coupled to the tubular support memberthat includes a first drag block body defining a slot for receiving andmating with the L-shaped retaining member of the split ring collar, anda first J-shaped slot for receiving the first lug, and one or more firstdrag blocks coupled to the first drag block body. A second drag blockassembly is movably coupled to the tubular support member that includesa second drag block body defining a second J-shaped slot for receivingthe second lug, and one or more second drag blocks coupled to the seconddrag block body. First and second packer cups are coupled to the tubularsupport member between the first and second drag block assemblies.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage, a first flange coupled to the first tubularsupport body, a second flange coupled to the first tubular support body,a first tapered flange coupled to the first tubular support body, asecond tapered flange coupled to the first tubular support body, and anexpansion cone support body coupled to the first tubular support body.The expansion cone support body includes an N-sided tapered tubularsupport member, wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot. N expansion cone segments aremovably coupled to the expansion cone support body, each including anexpansion cone segment body including arcuate conical outer surfaces, afirst T-shaped retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody, and a second T-shaped retaining member coupled to the expansioncone segment body. A split ring collar is movably coupled to theexterior of the tubular support member that includes a second tubularsupport body that defines N T-shaped slots for movably receivingcorresponding ones of the second T-shaped retaining members of theexpansion cone segments, and an L-shaped retaining member coupled to thesecond tubular support body. A first collet assembly is movably coupledto the tubular support member that includes a first tubular sleeve thatdefines a slot for receiving and mating with the L-shaped retainingmember of the split ring collar, a first counterbore for receiving thefirst flange, and a first radial passage, a first spring received withinthe first counterbore, a first retaining ring received within the firstcounterbore, a first load transfer pin coupled to the first retainingring and extending through the first radial passage, a second tubularsleeve coupled to the first load transfer pin, a first resilient colletcoupled to the second tubular sleeve and positioned above the firsttapered flange, and a third tubular sleeve coupled to the firstresilient collet. A second collet assembly is movably coupled to thetubular support member that includes a fourth tubular sleeve thatdefines a second counterbore for receiving the second flange, and asecond radial passage, a second spring received within the secondcounterbore, a second retaining ring received within the secondcounterbore, a second load transfer pin coupled to the second retainingring and extending through the second radial passage, a fifth tubularsleeve coupled to the second load transfer pin, a second resilientcollet coupled to the fifth tubular sleeve and positioned above thesecond tapered flange, and a sixth tubular sleeve coupled to the secondresilient collet. First and second packer cups coupled to the tubularsupport member between the first and second collet assemblies.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage, a first radial passage defined in the firsttubular support body fluidicly coupled to the longitudinal passage, afirst flange coupled to the first tubular support body, a second flangecoupled to the first tubular support body, a first tapered flangecoupled to the first tubular support body, a second tapered flangecoupled to the first tubular support body, and an expansion cone supportbody coupled to the first tubular support body. The expansion conesupport body includes an N-sided tapered tubular support member, whereineach side of the multi-sided tapered tubular support member defines aT-shaped slot. N expansion cone segments are movably coupled to theexpansion cone support body, each including an expansion cone segmentbody including arcuate conical outer surfaces, a first T-shapedretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theT-shaped slots of the expansion cone support body, and a second T-shapedretaining member coupled to the expansion cone segment body. A splitring collar is movably coupled to the exterior of the tubular supportmember that includes a second tubular support body that defines NT-shaped slots for movably receiving corresponding ones of the secondT-shaped retaining members of the expansion cone segments, and anL-shaped retaining member coupled to the second tubular support body. Afirst dog assembly is movably coupled to the tubular support member thatincludes a first tubular sleeve that defines a slot for receiving andmating with the L-shaped retaining member of the split ring collar, afirst counterbore for receiving the first flange, and a second radialpassage, a first spring received within the first counterbore, a firstretaining ring received within the first counterbore, a first loadtransfer pin coupled to the first retaining ring and extending throughthe second radial passage, and a second tubular sleeve coupled to thefirst load transfer pin that defines a second counterbore for receivingthe first tubular sleeve, a first resilient dog coupled to the secondtubular sleeve and positioned adjacent to the first tapered flange. Asecond dog assembly is movably coupled to the tubular support memberthat includes a third tubular sleeve that defines a second counterborefor receiving the second flange, a third radial passage, and a fourthradial passage fluidicly coupled to the first radial passage, a secondspring received within the second counterbore, a second retaining ringreceived within the second counterbore, a second load transfer pincoupled to the second retaining ring and extending through the thirdradial passage, a fourth tubular sleeve coupled to the second loadtransfer pin, and a second resilient dog coupled to the fourth tubularsleeve and positioned adjacent to the second tapered flange. First andsecond packer cups are coupled to the tubular support member between thefirst and second dog assemblies.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage including a throat passage, a first radial passagedefined in the first tubular support body fluidicly coupled to thelongitudinal passage, a first flange coupled to the first tubularsupport body, a second flange coupled to the first tubular support bodythat defines a second radial passage defined in the second flangefluidicly coupled to the longitudinal passage, a tapered flange coupledto the first tubular support body, and an expansion cone support bodycoupled to the first tubular support body. The expansion cone supportbody includes an N-sided tapered tubular support member, wherein eachside of the multi-sided tapered tubular support member defines aT-shaped slot. N expansion cone segments are movably coupled to theexpansion cone support body, each including an expansion cone segmentbody including arcuate conical outer surfaces, a first T-shapedretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theT-shaped slots of the expansion cone support body, and a second T-shapedretaining member coupled to the expansion cone segment body. A splitring collar is movably coupled to the exterior of the tubular supportmember that includes a second tubular support body that defines NT-shaped slots for movably receiving corresponding ones of the secondT-shaped retaining members of the expansion cone segments, and anL-shaped retaining member coupled to the second tubular support body. Adog assembly is movably coupled to the tubular support member thatincludes a first tubular sleeve that defines a slot for receiving andmating with the L-shaped retaining member of the split ring collar, afirst counterbore for receiving the first flange, and a third radialpassage, a spring received within the first counterbore, a retainingring received within the first counterbore, a load transfer pin coupledto the retaining ring and extending through the third radial passage, asecond tubular sleeve coupled to the first load transfer pin thatdefines a first counterbore for receiving the first tubular sleeve, asecond counterbore for receiving and mating with the tapered flange, andincludes a third flange that defines a third counterbore for receivingthe second flange, a fourth counterbore for receiving the second flange,and a fourth radial passage, and a resilient dog coupled to the secondtubular sleeve and positioned adjacent to the tapered flange. First andsecond packer cups are coupled to the tubular support member between theresilient dog and the third flange.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a tubular supportmember that includes a tubular support body and an expansion conesupport body coupled to the tubular support body. The expansion conesupport body includes an N-sided tapered tubular support member, whereineach side of the multi-sided tapered tubular support member defines aT-shaped slot. N expansion cone segments are movably coupled to theexpansion cone support body, each including an expansion cone segmentbody including arcuate conical outer surfaces, a first T-shapedretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theT-shaped slots of the expansion cone support body, and a second T-shapedretaining member coupled to the expansion cone segment body. A splitring collar is movably coupled to the exterior of the tubular supportmember that includes a second tubular support body that defines NT-shaped slots for movably receiving corresponding ones of the secondT-shaped retaining members of the expansion cone segments, and anL-shaped retaining member coupled to the second tubular support body. Atubular actuating sleeve is movably coupled to the tubular supportmember that includes a third tubular support body that defines a slotfor receiving and mating with the L-shaped retaining member of the splitring collar.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a tubular supportmember that includes a first tubular support body, and an expansion conesupport body coupled to the tubular support body. The expansion conesupport body includes a tapered tubular support member defining Nstepped slots. An expansion cone assembly is movably coupled to thetubular support member that includes a second tubular support bodymovably coupled to the first tubular support body defining an L-shapedslot, and N expansion cone segments extending from the second tubularsupport member. Each expansion cone segment includes a resilient colletcoupled to the second tubular support member, an expansion cone segmentbody coupled to the resilient collet including arcuate conical outersurfaces, and a retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the stepped slots of the expansion cone supportbody. A split ring collar is movably coupled to the exterior of thetubular support member that includes a third tubular support body, afirst L-shaped retaining member coupled to the third tubular supportbody for mating with the L-shaped slot of the second tubular supportbody of the expansion cone assembly, and a second L-shaped retainingmember coupled to the third tubular body. A tubular actuating sleeve ismovably coupled to the tubular support member that includes a thirdtubular support body that defines a slot for receiving and mating withthe second L-shaped retaining member of the split ring collar.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a tubular supportmember that includes a first tubular support body, and an expansion conesupport body coupled to the tubular support body. The expansion conesupport body includes a tapered tubular support member defining N slots.An expansion cone assembly is movably coupled to the tubular supportmember that includes a second tubular support body movably coupled tothe first tubular support body defining an L-shaped slot, and Nexpansion cone segments extending from the second tubular supportmember. Each expansion cone segment includes a resilient collet coupledto the second tubular support member, an expansion cone segment bodycoupled to the resilient collet including arcuate conical outersurfaces, and a retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the slots of the expansion cone support body. Asplit ring collar is movably coupled to the exterior of the tubularsupport member that includes a third tubular support body, a firstL-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body, and asecond L-shaped retaining member coupled to the third tubular supportbody. A tubular actuating sleeve is movably coupled to the tubularsupport member that includes a third tubular support body that defines aslot for receiving and mating with the second L-shaped retaining memberof the split ring collar.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a tubular supportmember that includes a first tubular support body, and an expansion conesupport body coupled to the tubular support body. The expansion conesupport body includes a tapered tubular support member defining N slots.An expansion cone assembly is movably coupled to the tubular supportmember that includes a second tubular support body movably coupled tothe first tubular support body defining an L-shaped slot, N/2 firstexpansion cone segments extending from the second tubular supportmember, and N/2 second expansion cone segments extending from the secondtubular member. Each first expansion cone segment includes a firstresilient collet coupled to the second tubular support member, a firstexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces, and a first retaining member coupled tothe expansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body. Each second expansion cone segment includes a secondresilient collet coupled to the second tubular support member, a secondexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces, and a second retaining member coupled tothe expansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body. The second expansion cone segments overlap and areinterleaved with the first expansion cone segments. A split ring collaris movably coupled to the exterior of the tubular support member thatincludes a third tubular support body, a first L-shaped retaining membercoupled to the third tubular support body for mating with L-shaped slotof the second tubular support body, and a second L-shaped retainingmember coupled to the third tubular support body. A tubular actuatingsleeve is movably coupled to the tubular support member that includes athird tubular support body that defines a slot for receiving and matingwith the second L-shaped retaining member of the split ring collar.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a tubular supportmember that includes a first tubular support body, and an expansion conesupport body coupled to the first tubular support body. The expansioncone support body includes an N-sided tapered tubular support member,wherein each side of the multi-sided tapered tubular support memberdefines a T-shaped slot. N/2 first expansion cone segments are movablycoupled to the expansion cone support body, each including a firstexpansion cone segment body including arcuate conical outer surfaces, afirst T-shaped retaining member coupled to the first expansion conesegment body for movably coupling the first expansion cone segment bodyto a corresponding one of the T-shaped slots of the expansion conesupport body, and a second T-shaped retaining member coupled to thefirst expansion cone segment body. N/2 second expansion cone segmentsare also movably coupled to the expansion cone support body, eachincluding a second expansion cone segment body including arcuate conicalouter surfaces, a third T-shaped retaining member coupled to the secondexpansion cone segment body for movably coupling the second expansioncone segment body to a corresponding one of the T-shaped slots of theexpansion cone support body, and a fourth T-shaped retaining membercoupled to the expansion cone segment body. The first and secondexpansion cone segments are interleaved. The first expansion conesegment bodies are complementary shaped with respect to the secondexpansion cone segment bodies. A split ring collar assembly is movablycoupled to the exterior of the tubular support member that includes asecond tubular support body that defines N T-shaped slots for movablyreceiving corresponding ones of the second and fourth T-shaped retainingmembers of the interleaved first and second expansion cone segments, andan L-shaped retaining member coupled to the second tubular support body.A tubular actuating sleeve movably coupled to the tubular support memberthat includes a third tubular support body that defines a slot forreceiving and mating with the L-shaped retaining member of the splitring collar.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage, a first lug coupled to and extending from thefirst tubular support body in the radial direction, and a second lugcoupled to and extending from the first tubular support body in theradial direction. An adjustable expansion cone assembly is movablycoupled to the tubular support member. A first drag block assembly ismovably coupled to the tubular support member that includes a first dragblock body coupled to the adjustable expansion cone assembly thatdefines: a first J-shaped slot for receiving the first lug, and one ormore first drag blocks coupled to the first drag block body. A seconddrag block assembly is movably coupled to the tubular support memberthat includes a second drag block body that defines: a second J-shapedslot for receiving the second lug, and

one or more second drag blocks coupled to the second drag block body.First and second packer cups are coupled to the tubular support memberbetween the first and second drag block assemblies.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage, a first flange coupled to the first tubularsupport body, a second flange coupled to the first tubular support body,a first tapered flange coupled to the first tubular support body, and asecond tapered flange coupled to the first tubular support body. Anadjustable expansion cone assembly is movably coupled to the tubularsupport member. A first collet assembly is movably coupled to thetubular support member that includes a first tubular sleeve coupled tothe adjustable expansion cone assembly and defines a first counterborefor receiving the first flange, and a first radial passage, a firstspring received within the first counterbore, a first retaining ringreceived within the first counterbore, a first load transfer pin coupledto the first retaining ring and extending through the first radialpassage, a second tubular sleeve coupled to the first load transfer pin,a first resilient collet coupled to the second tubular sleeve andpositioned above the first tapered flange, and a third tubular sleevecoupled to the first resilient collet. A second collet assembly ismovably coupled to the tubular support member that includes a fourthtubular sleeve that defines: a second counterbore for receiving thesecond flange, and a second radial passage, a second spring receivedwithin the second counterbore, a second retaining ring received withinthe second counterbore, a second load transfer pin coupled to the secondretaining ring and extending through the second radial passage, a fifthtubular sleeve coupled to the second load transfer pin, a secondresilient collet coupled to the fifth tubular sleeve and positionedabove the second tapered flange, and a sixth tubular sleeve coupled tothe second resilient collet. First and second packer cups are coupled tothe tubular support member between the first and second colletassemblies.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage, a first radial passage defined in the firsttubular support body fluidicly coupled to the longitudinal passage, afirst flange coupled to the first tubular support body, a second flangecoupled to the first tubular support body, a first tapered flangecoupled to the first tubular support body, and a second tapered flangecoupled to the first tubular support body. An adjustable expansion coneassembly is movably coupled to the tubular support member. A first dogassembly is movably coupled to the tubular support member that includesa first tubular sleeve coupled to the adjustable expansion cone assemblythat defines: a first counterbore for receiving the first flange, and asecond radial passage, a first spring received within the firstcounterbore, a first retaining ring received within the firstcounterbore, a first load transfer pin coupled to the first retainingring and extending through the second radial passage, a second tubularsleeve coupled to the first load transfer pin that defines: a secondcounterbore for receiving the first tubular sleeve, a first resilientdog coupled to the second tubular sleeve and positioned adjacent to thefirst tapered flange. A second dog assembly is movably coupled to thetubular support member that includes a third tubular sleeve that definesa second counterbore for receiving the second flange;

a third radial passage, and a fourth radial passage fluidicly coupled tothe first radial passage, a second spring received within the secondcounterbore, a second retaining ring received within the secondcounterbore, a second load transfer pin coupled to the second retainingring and extending through the third radial passage, a fourth tubularsleeve coupled to the second load transfer pin, a second resilient dogcoupled to the fourth tubular sleeve and positioned adjacent to thesecond tapered flange. First and second packer cups are coupled to thetubular support member between the first and second dog assemblies.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member that includes a first tubular support body defining alongitudinal passage including a throat passage, a first radial passagedefined in the first tubular support body fluidicly coupled to thelongitudinal passage, a first flange coupled to the first tubularsupport body, and a second flange coupled to the first tubular supportbody that defines: a second radial passage defined in the second flangefluidicly coupled to the longitudinal passage. An adjustable expansioncone assembly is movably coupled to the tubular support member. A dogassembly is movably coupled to the tubular support member that includesa first tubular sleeve coupled to the adjustable expansion cone assemblythat defines a first counterbore for receiving the first flange, and athird radial passage, a spring received within the first counterbore, aretaining ring received within the first counterbore, a load transferpin coupled to the retaining ring and extending through the third radialpassage, a second tubular sleeve coupled to the first load transfer pinthat defines: a first counterbore for receiving the first tubularsleeve, a second counterbore for receiving and mating with the taperedflange, and includes a third flange that defines a third counterbore forreceiving the second flange, a fourth counterbore for receiving thesecond flange, and a fourth radial passage, and a resilient dog coupledto the second tubular sleeve and positioned adjacent to the taperedflange. First and second packer cups are coupled to the tubular supportmember between the resilient dog and the third flange.

According to another aspect of the present invention, an apparatus forradially expanding a tubular member is provided that includes a tubularsupport member, an adjustable expansion cone assembly movably coupled tothe tubular support member, and means for adjusting the adjustableexpansion cone assembly.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a tubular supportmember. An adjustable expansion cone is movably coupled to the tubularsupport member that includes a plurality of expansion cone segments, andmeans for guiding the expansion cone segments on the tubular supportmember. The assembly further includes means for adjusting the adjustableexpansion cone.

According to another aspect of the present invention, a method ofoperating an adjustable expansion cone assembly including a plurality ofexpansion cone segments is provided that includes guiding the expansioncone segments on a tapered body, and controllably displacing theexpansion cone segments along the tapered body.

According to another aspect of the present invention, a method ofoperating an adjustable expansion cone assembly including a plurality ofexpansion cone segments is provided that includes guiding the expansioncone segments on a multi-sided tapered body, interlocking the expansioncone segments, and controllably displacing the expansion cone segmentsalong the tapered body.

According to another aspect of the present invention, a method ofoperating an adjustable expansion cone assembly including a plurality ofexpansion cone segments is provided that includes resiliently guidingthe expansion cone segments on a multi-sided tapered body, guiding eachof the expansion cone segments on opposite sides in the circumferentialdirection, interlocking the expansion cone segments, and controllablydisplacing the expansion cone segments along the tapered body.

According to another aspect of the present invention, a method ofoperating an adjustable expansion cone assembly including a plurality ofexpansion cone segments is provided that includes dividing the expansioncone segments into first and second groups of expansion cone segments,interleaving the first and second groups of expansion cone segments,overlapping the first and second groups of expansion cone segments,resiliently guiding the expansion cone segments on a multi-sided taperedbody, guiding each of the expansion cone segments on opposite sides inthe circumferential direction, and controllably displacing the expansioncone segments along the tapered body.

According to another aspect of the present invention, a method ofoperating an adjustable expansion cone assembly including a plurality ofexpansion cone segments is provided that includes dividing the expansioncone segments into first and second groups of expansion cone segments,interleaving the first and second groups of expansion cone segments,guiding the expansion cone segments on a multi-sided tapered body, andcontrollably displacing the expansion cone segments along the taperedbody while also relatively displacing the first and second groups ofexpansion cone segments in opposite directions.

According to another aspect of the present invention, a method ofplastically deforming and radially expanding an expandable tubularmember using an apparatus including a tubular support member, anadjustable expansion cone assembly movably coupled to the tubularsupport member, and an actuator movably coupled to the tubular supportmember for adjusting the adjustable expansion cone assembly, is providedthat includes coupling a first end of the expandable tubular member to atubular structure, locking the actuator to the tubular support member ofthe apparatus, inserting the apparatus into the first end of theexpandable tubular member, moving the actuator and the adjustableexpansion cone assembly of the apparatus out of the second end of theexpandable tubular member, reinserting the actuator of the apparatusinto the second end of the expandable tubular member, unlocking theactuator from the tubular support member of the apparatus, rotating theactuator relative to the tubular support member of the apparatus, andincreasing the outside diameter of the adjustable expansion coneassembly by moving the tubular support member relative to the actuator,the adjustable expansion cone assembly and the expandable tubularmember, and plastically deforming and radially expanding the expandabletubular member by moving the adjustable expansion cone assembly throughthe expandable tubular member.

According to another aspect of the present invention, a method ofplastically deforming and radially expanding an expandable tubularmember using an apparatus including a tubular support member, anadjustable expansion cone assembly movably coupled to the tubularsupport member, and an actuator movably coupled to the tubular supportmember for adjusting the adjustable expansion cone assembly, is providedthat includes coupling a first end of the expandable tubular member to atubular structure, inserting the apparatus into the first end of theexpandable tubular member in a first direction, displacing the actuatorof the apparatus in a second direction opposite to the first direction,applying a resilient biasing force to the adjustable expansion coneassembly in the second direction, moving the actuator and the adjustableexpansion cone assembly of the apparatus out of the second end of theexpandable tubular member, reinserting the actuator of the apparatusinto the second end of the expandable tubular member in the seconddirection, increasing the outside diameter of the adjustable expansioncone assembly by displacing the actuator and the adjustable expansioncone assembly relative to the expandable tubular member in the firstdirection, and plastically deforming and radially expanding theexpandable tubular member by moving the adjustable expansion coneassembly through the expandable tubular member in the second direction.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a plurality ofexpansion cone segments, means for guiding the expansion cone segmentson a tapered body, and means for controllably displacing the expansioncone segments along the tapered body.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a plurality ofexpansion cone segments, means for guiding the expansion cone segmentson a multi-sided tapered body, means for interlocking the expansion conesegments, and means for controllably displacing the expansion conesegments along the tapered body.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a plurality ofexpansion cone segments, means for resiliently guiding the expansioncone segments on a multi-sided tapered body, means for guiding each ofthe expansion cone segments on opposite sides in the circumferentialdirection, means for interlocking the expansion cone segments, and meansfor controllably displacing the expansion cone segments along thetapered body.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a plurality ofexpansion cone segments, means for dividing the expansion cone segmentsinto first and second groups of expansion cone segments, means forinterleaving the first and second groups of expansion cone segments,means for overlapping the first and second groups of expansion conesegments, means for resiliently guiding the expansion cone segments on amulti-sided tapered body, means for guiding each of the expansion conesegments on opposite sides in the circumferential direction, and meansfor controllably displacing the expansion cone segments along thetapered body.

According to another aspect of the present invention, an adjustableexpansion cone assembly is provided that includes a plurality ofexpansion cone segments, means for dividing the expansion cone segmentsinto first and second groups of expansion cone segments, means forinterleaving the first and second groups of expansion cone segments,means for guiding the expansion cone segments on a multi-sided taperedbody, and means for controllably displacing the expansion cone segmentsalong the tapered body while also relatively displacing the first andsecond groups of expansion cone segments in opposite directions.

According to another aspect of the present invention, an apparatus forplastically deforming and radially expanding an expandable tubularmember is provided that includes a tubular support member, an adjustableexpansion cone assembly movably coupled to the tubular support member,means for actuating the adjustable expansion cone assembly, means forlocking the actuator to the tubular support member of the apparatus,means for unlocking the actuator from the tubular support member of theapparatus, and means for increasing the outside diameter of theadjustable expansion cone assembly by moving the tubular support memberrelative to the actuator, the adjustable expansion cone assembly, andthe expandable tubular member.

According to another aspect of the present invention, an apparatus forplastically deforming and radially expanding an expandable tubularmember is provided that includes a tubular support member, an adjustableexpansion cone assembly movably coupled to the tubular support member,means for actuating the adjustable expansion cone assembly, means fordisplacing the actuator of the apparatus in a first direction, means forapplying a resilient biasing force to the adjustable expansion coneassembly when the actuator is displaced in the first direction, andmeans for increasing the outside diameter of the adjustable expansioncone assembly by displacing the actuator and the adjustable expansioncone assembly relative to the expandable tubular member in a seconddirection opposite to the first direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 1 a-1 d are fragmentary cross-sectional views of anembodiment of the placement of an apparatus for radially expanding atubular member within a tubular member within a borehole within asubterranean formation.

FIG. 1 e is a cross-sectional view of an embodiment of the expansioncone support body of the apparatus of FIGS. 1 and 1 a-1 d.

FIG. 1 f is a cross-sectional view of the expansion cone support body ofFIG. 1 e.

FIG. 1 g is a side view of an embodiment of an expansion cone segmentfor use in the apparatus of FIGS. 1 and 1 a-1 d.

FIG. 1 h is a front view of the expansion cone segment of FIG. 1 g.

FIG. 1 i is a top view of the expansion cone segment of FIG. 1 g.

FIG. 1 j is a top view of an embodiment of interlocking expansion conesegments for use in the apparatus of FIGS. 1 and 1 a-1 d.

FIG. 1 k is a top fragmentary circumferential view of an embodiment ofthe coupling arrangement between the expansion cone segments and thesplit ring collar for use in the apparatus of FIGS. 1 and 1 a-1 d.

FIGS. 1 l and 1 m are top schematic views of an embodiment of thecoupling between the J-slots of the drag blocks and the lugs of thetubular support member of the apparatus of FIGS. 1 and 1 a-1 d.

FIGS. 2 and 2 a-2 d are fragmentary cross-sectional illustrations of theapparatus of FIGS. 1 and 1 a-1 d during the radial expansion of thetubular member within the borehole within the subterranean formation.

FIGS. 2 e and 2 f are illustrations of an embodiment of the J-slots ofthe drag blocks and the lugs of the tubular support member of theapparatus of FIGS. 2 and 2 a-2 d.

FIGS. 2 g and 2 h are illustrations of an alternative embodiment of theJ-slots of the drag blocks and the lugs of the tubular support member ofthe apparatus of FIGS. 2 and 2 a-2 d.

FIGS. 3 and 3 a-3 c are fragmentary cross-sectional illustrations of anembodiment of the placement of an apparatus for radially expanding atubular member within a wellbore casing within a subterranean formation.

FIG. 3 d is a cross-sectional view of an embodiment of the expansioncone support body of the apparatus of FIGS. 3 and 3 a-3 c.

FIG. 3 e is a cross-sectional view of the expansion cone support body ofFIG. 3 d.

FIG. 3 f is a side view of an embodiment of an expansion cone segmentfor use in the apparatus of FIGS. 3 and 3 a-3 c.

FIG. 3 g is a front view of the expansion cone segment of FIG. 3 f.

FIG. 3 h is a top view of the expansion cone segment of FIG. 3 f.

FIG. 3 i is a top view of an embodiment of interlocking expansion conesegments for use in the apparatus of FIGS. 3 and 3 a-3 c.

FIG. 3 j is a top fragmentary circumferential view of an embodiment ofthe coupling arrangement between the expansion cone segments and thesplit ring collar for use in the apparatus of FIGS. 3 and 3 a-3 c.

FIGS. 4 and 4 a-4 d are fragmentary cross-sectional illustrations of anembodiment of the placement of the apparatus of FIGS. 3 and 3 a-3 cincluding an expandable tubular member within an expandable tubularmember within a subterranean formation.

FIGS. 5 and 5 a-5 d are fragmentary cross-sectional illustrations of anembodiment of the operation of the apparatus of FIGS. 4 and 4 a-4 dduring the radial expansion of the expandable tubular member within theborehole within the subterranean formation.

FIGS. 6 and 6 a-6 d are fragmentary cross-sectional illustrations of anembodiment of the placement of an apparatus for radially expanding atubular member within a borehole within a subterranean formation.

FIG. 6 eis a cross-sectional view of an embodiment of the expansion conesupport body of the apparatus of FIGS. 6 and 6 a-6 d.

FIG. 6 fis a cross-sectional view of the expansion cone support body ofFIG. 6 e.

FIG. 6 gis a side view of an embodiment of an expansion cone segment foruse in the apparatus of FIGS. 6 and 6 a-6 d.

FIG. 6 h is a front view of the expansion cone segment of FIG. 6 g.

FIG. 6 i is a top view of the expansion cone segment of FIG. 6 g.

FIG. 6 j is a top view of an embodiment of interlocking expansion conesegments for use in the apparatus of FIGS. 6 and 6 a-6 d.

FIG. 6 k is a top fragmentary circumferential view of an embodiment ofthe coupling arrangement between the expansion cone segments and thesplit ring collar for use in the apparatus of FIGS. 6 and 6 a-6 d.

FIGS. 7 and 7 a-7 c are fragmentary cross-sectional illustrations of anembodiment of the placement of the apparatus of FIGS. 6 and 6 a-6 dincluding an expandable tubular member within a borehole within asubterranean formation.

FIGS. 8 and 8 a-8 d are fragmentary cross-sectional illustrations of anembodiment of the operation of the apparatus of FIGS. 7 and 7 a-7 dduring the radial expansion of the expandable tubular member within aborehole within a subterranean formation.

FIG. 9 is a fragmentary cross sectional illustration of an embodiment ofan expansion cone assembly in an unexpanded position.

FIG. 9 a is a cross sectional illustration of the expansion coneassembly of FIG. 9.

FIG. 10 is a fragmentary cross sectional illustration of the expansioncone assembly of FIG. 9 in an expanded position.

FIG. 10 a is a cross sectional illustration of the expansion coneassembly of FIG. 10.

FIG. 11 is a fragmentary cross sectional illustration of an embodimentof an expansion cone assembly in an unexpanded position.

FIG. 11 a is a cross sectional illustration of the expansion coneassembly of FIG. 11.

FIG. 12 is a fragmentary cross sectional illustration of the expansioncone assembly of FIG. 11 in an expanded position.

FIG. 12 a is a cross sectional illustration of the expansion coneassembly of FIG. 12.

FIG. 13 is a fragmentary cross sectional illustration of an embodimentof an expansion cone assembly in an unexpanded position.

FIG. 13 a is a cross sectional illustration of the expansion coneassembly of FIG. 13.

FIG. 13 b is a fragmentary top circumferential illustration of theexpansion cone segment assembly of FIG. 13 that illustrates theinterleaved sets of collets.

FIG. 13 c is a fragmentary cross sectional illustration of theinterleaved collets of FIG. 13 b.

FIG. 14 is a fragmentary cross sectional illustration of the expansioncone assembly of FIG. 13 in an expanded position.

FIG. 14 a is a cross sectional illustration of the expansion coneassembly of FIG. 14.

FIGS. 15 and 15 a-15 c are fragmentary cross-sectional illustrations ofan embodiment of the placement of an apparatus for radially expanding atubular member within a borehole within a subterranean formation.

FIG. 15 d is a cross-sectional view of an embodiment of the expansioncone support body of the apparatus of FIGS. 15 and 15 a-15 c.

FIG. 15 e is a cross-sectional view of the expansion cone support bodyof FIG. 15 d.

FIG. 15 f is a side view of an embodiment of an expansion cone segmentfor use in the apparatus of FIGS. 15 and 15 a-15 c.

FIG. 15 g is a front view of the expansion cone segment of FIG. 15 f.

FIG. 15 h is a top view of the expansion cone segment of FIG. 15 f.

FIG. 15 i is a top view of an embodiment of interlocking expansion conesegments for use in the apparatus of FIGS. 15 and 15 a-15 c.

FIG. 15 j is a top fragmentary circumferential view of an embodiment ofthe coupling arrangement between the expansion cone segments and thesplit ring collar for use in the apparatus of FIGS. 15 and 15 a-15 c.

FIGS. 16 and 16 a-16 c are fragmentary cross-sectional illustrations ofan embodiment of the placement of the apparatus of FIGS. 15 and 15 a-15j including an expandable tubular member within a borehole within asubterranean formation.

FIGS. 17 and 17 a-17 c are fragmentary cross-sectional illustrations ofan embodiment of the operation of the apparatus of FIGS. 16 and 16 a-16c during the radial expansion of the expandable tubular member within aborehole within a subterranean formation.

FIG. 18 a is a cross sectional illustration of an embodiment of asegmented expansion cone assembly in an unexpanded position.

FIG. 18 b is a fragmentary circumferential top illustration of theexpansion cone and split ring collar of FIG. 18 a.

FIG. 18 c is a fragmentary cross-sectional illustration of the expansioncone support flange of the expansion cone assembly of FIG. 18 a.

FIG. 18 d is a cross-sectional illustration of the expansion conesupport flange of FIG. 18 c.

FIG. 19 a is a cross sectional illustration of an embodiment of thesegmented expansion cone assembly of FIG. 18 a in an expanded position.

FIG. 19 b is a fragmentary circumferential top view of the expansioncone of FIG. 19 a.

FIGS. 20 a-20 m are top circumferential views of various alternativeembodiments of interlocking expansion cone segment geometries.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIGS. 1 and 1 a-1 d, an embodiment of anapparatus and method for radially expanding a tubular member will now bedescribed. As illustrated in FIGS. 1 and 1 a-1 d, a wellbore 100 ispositioned in a subterranean formation 105. In an exemplary embodiment,the wellbore 100 may include a pre-existing cased section 110. Thewellbore 100 may be positioned in any orientation from vertical tohorizontal.

In order to extend the wellbore 100 into the subterranean formation 105,a drill string is used in a well known manner to drill out material fromthe subterranean formation 105 to form a new wellbore section 115. In apreferred embodiment, the inside diameter of the new wellbore section115 is greater than or equal to the inside diameter of the preexistingwellbore casing 110.

A tubular member 120 defining a passage 120 a may then be positionedwithin the wellbore section 115 with the upper end 120 b of the tubularmember coupled to the wellbore casing 110 and the lower end 120 c of thetubular member extending into the wellbore section. The tubular member120 may be positioned within the wellbore section 115 and coupled to thewellbore casing 110 in a conventional manner. In a preferred embodiment,the tubular member 120 is positioned within the wellbore section 115 andcoupled to the wellbore casing 110 using one or more of the methods andapparatus disclosed in one or more of the following: (1) U.S. Pat. No.6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, whichclaims priority from provisional application 60/121,702, filed on Feb.25, 1999, (3) U.S. Pat. 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As illustrated in FIGS. 1 and 1 a-1 d, an apparatus 200 for radiallyexpanding a tubular member may then be positioned in the new section 115of the wellbore 100 within the tubular member 120. The apparatus 200includes a tubular support member 205 defining an internal passage 205 athat is coupled to an end of a tubular coupling 210 defining an internalpassage 210 a. The other end of the tubular coupling 210 is coupled toan end of a tubular support member 215 defining an internal passage 215a that includes a first lug 215 b, a radial passage 215 c, a firstflange 215 d, a second flange 215 e, a second lug 215 f, and anexpansion cone support body 215 g. The other end of the tubular supportmember 215 is coupled to a tubular end stop 220 that defines a passage220 a.

As illustrated in FIGS. 1 e and 1 f, the expansion cone support body 215g includes a first end 215 ga, a tapered hexagonal portion 215 gb thatincludes a plurality of T-shaped slots 215 gba provided on each of theexternal faceted surfaces of the tapered hexagonal portion, and a secondend 215 gc. In an exemplary embodiment, the angle of attack of thetapered hexagonal portion ranges from about 35 to 50 degrees for reasonsto be described.

As illustrated in FIGS. 1, 1 a-1 d, 1 g,1 h, and 1 i, a plurality ofexpansion cone segments 225 are provided that include first ends 225 athat include T-shaped retaining members 225 aa and second ends 225 bthat include T-shaped retaining members 225 ba that mate with and arereceived within corresponding T-shaped slots 215 gba on the taperedhexagonal portion 215 gb of the expansion cone support body 215 g, firstexternal surfaces 225 bb, second external surfaces 225 bc, and thirdexternal surfaces 225 bd. Thus, in an exemplary embodiment, a total ofsix expansion cone segments 225 are provided that are slidably coupledto corresponding sides of the tapered hexagonal portion 215 gb of theexpansion cone support body.

In an exemplary embodiment, the widths of the first external surfaces225 bb of the expansion cone segments 225 increase in the direction ofthe second external surfaces 225 bc, the widths of the second externalsurfaces are substantially constant, and the widths of the thirdexternal surfaces 225 bd decrease in the direction of the first ends 225a of the expansion cone segments for reasons to be described. In anexemplary embodiment, the first external surfaces 225 bb of theexpansion cone segments 225 taper upwardly in the direction of thesecond external surfaces 225 bc, the second external surfaces taperupwardly in the direction of the third external surfaces 225 bd, and thethird external surfaces 225 bd taper downwardly in the direction of thefirst ends 225 a of the expansion cone segments for reasons to bedescribed. In an exemplary embodiment, the angle of attack of the taperof the first external surfaces 225 bb of the expansion cone segments 225are greater than the angle of attack of the taper of the second externalsurfaces 225 bc. In an exemplary embodiment, the first and secondexternal surfaces, 225 bb and 225 bc, of the expansion cone segments 225are arcuate such that when the expansion cone segments 225 are displacedin the direction of the end stop 220, the first and second externalsurfaces of the expansion cone segments provide a substantiallycontinuous outer circumferential surface for reasons to be described.

As illustrated in FIG. 1 j, in an exemplary embodiment, the externalsurfaces, 225 bb, 225 bc, and 225 bd, of the second ends 225 b of theexpansion cone segments 225 are adapted to mate with one another inorder to interlock adjacent expansion cone segments.

As illustrated in FIGS. 1, 1 a-1 d, and 1 k, a split ring collar 230that defines a passage 230 a for receiving the tubular support member215 is provided that includes a first end that includes plurality ofT-shaped slots 230 b for receiving and mating with correspondingT-shaped retaining members 225 aa of the expansion cone segments 225 anda second end that includes an L-shaped retaining member 230 c. In anexemplary embodiment, the split ring collar 230 is a conventional splitring collar commercially available from Halliburton Energy Servicesmodified in accordance with the teachings of the present disclosure.

As illustrated in FIGS. 1, 1 a-1 d, and 1 m, a drag block assembly 235that defines a passage 235 a for receiving the tubular support member215 is provided that includes a first end that includes an L-shaped slot235 b for receiving and mating with the L-shaped retaining member 230 cof the split ring collar 230, one or more conventional drag blockelements 235 c, and a J-shaped slot 235 d including a retaining slot 235da for receiving the second lug 215 f of the tubular support member 215.In an exemplary embodiment, the longitudinal axis of the J-shaped slot235 d of the drag block assembly 235 is substantially parallel to thelongitudinal axis of the tubular support member 215 for reasons to bedescribed.

A first conventional packer cup assembly 240 that defines a passage 240a for receiving the tubular support member 215 includes a first end 240b that mates with the second flange 215 e of the tubular support member,a conventional sealing cup 240 c, and a second end 240 d. A tubularspacer 245 that defines a passage 245 a for receiving the tubularsupport member 215 includes a first end 245 b that mates with the secondend 240 c of the first packer cup assembly 240 and a second end 245 c. Asecond conventional packer cup assembly 250 that defines a passage 250 afor receiving the tubular support member 215 includes a first end 250 bthat mates with the second end 245 c of the spacer 245, a conventionalsealing cup 250 c, and a second end 250 d that mates with the firstflange 215 d of the tubular support member.

As illustrated in FIGS. 1, 1 a-1 d, and 1 l, a drag block assembly 255that defines a passage 255 a for receiving the tubular support member215 is provided that includes a first end that includes sealing members,255 b and 255 c, one or more conventional drag block elements 255 d, anda J-shaped slot 255 e including a retaining slot 255 ea for receivingthe first lug 215 b of the tubular support member 215. In an exemplaryembodiment, the longitudinal axis of the J-shaped slot 255 e of the dragblock assembly 255 is substantially parallel to the longitudinal axis ofthe tubular support member 215 for reasons to be described.

In an exemplary embodiment, during operation of the apparatus 200, asillustrated in FIGS. 1 and 1 a-1 m, the apparatus may be positioned inthe wellbore 115, within the tubular member 120, with the first andsecond lugs, 215 b and 215 f, respectively, positioned within theretaining slots, 255 ea and 235 da, respectively, of the J-slots, 255 eand 235 da, respectively, of the drag block assembly 255 and 235,respectively. In this manner, the drag block assembly 235 is maintainedin a substantially stationary position relative to the tubular supportmember 215 thereby preventing the expansion cone segments 225 from beingdisplaced downwardly in the longitudinal direction relative to thetubular support member 215 towards the end stop 220. Furthermore, inthis manner, the drag block assembly 255 is also maintained in asubstantially stationary position relative to the tubular support member215 thereby preventing the drag block assembly from sealing off theradial passage 215 c. In an exemplary embodiment, during the placementof the apparatus 200 within the wellbore 115 and the tubular member 120,the radial passage 215 c permits fluidic materials outside of thetubular support member 215 to pass into the passage 215 a therebyminimizing overpressure conditions within the annulus outside of thetubular support member.

In an exemplary embodiment, the apparatus 200 is positioned within theexpandable tubular member 120 such that the expansion cone body 215 g,the end stop 220, and the expansion cone segments 225 extend out of theexpandable tubular member. In this manner, the expansion cone segments225 may be driven up the tapered hexagonal portion 215 gb of theexpansion cone body 215 g, thereby increasing the outside diameters ofthe expansion cone segments, without impacting the expandable tubularmember 120.

The tubular support member 215 may then be rotated relative to the dragblock assemblies, 235 and 255, thereby displacing the lugs, 215 f and215 b, with respect to the J-shaped slots, 235 d and 255 e,respectively. The tubular support member 215 may then be displacedupwardly relative to the drag block assemblies, 235 and 255, in thelongitudinal direction thereby displacing the drag block assembliesdownwardly relative to the tubular support member. During thelongitudinal upward displacement of the tubular support member 215relative to the drag block assemblies, 235 and 255, the drag blockassemblies, 235 and 255, are maintained in a substantially stationaryposition with respect to the expandable tubular member 120 by thefrictional forces exerted by the drag blocks, 235 c and 255 d, of thedrag block assemblies on the expandable tubular member, and during theupward longitudinal displacement of the tubular support member 215relative to the drag block assemblies, the lugs, 215 f and 215 b, areguided in a substantially longitudinal direction by the J-slots, 235 dand 255 e, respectively, of the drag block assemblies.

The downward longitudinal displacement of the drag block assembly 235relative to the tubular support member 215 displaces the split ringcollar 230 downwardly along with the expansion cone segments 225. As aresult, the expansion cone segments 225 are driven up the taperedhexagonal portion 215 gb of the expansion cone support body 215 g untilthe end faces of the expansion cone segments impact the stop member 220.As a result, the outside diameter of the expansion cone segments 225increases. In an exemplary embodiment, once the expansion cone segments225 impact the stop member 220, the outer surfaces, 225 bb and 225 bc,of the expansion cone segments provide a substantially continuous outersurface in the circumferential direction having a diameter that isgreater than the inside diameter of the expandable tubular member 120.The downward longitudinal displacement of the drag block assembly 255relative to the tubular support member 215 seals off the radial passage215 c thereby preventing the pressurized fluidic material 275 fromentering the annulus surrounding the tubular support member 215 throughthe radial passage.

In an exemplary embodiment, as illustrated in FIGS. 2 and 2 a-2 f, theexpandable tubular member 120 may then be radially expanded using theapparatus 200 by injecting a fluidic material 275 into the apparatusthrough the passages 205 a, 210 a, and 215 a. The injection of thefluidic material 275 may pressurize the interior 120 a of the expandabletubular member 120. In addition, because the packer cup assemblies, 240and 250, seal off an annular region 120 aa below the packer cupassemblies between the expandable tubular member 120 and the tubularsupport member 215, the injection of the fluidic material 275 may alsopressurize the annular region.

The continued injection of the fluidic material 275 may then pressurizethe interior 120 a of the expandable tubular member 120 therebyplastically deforming and radially expanding the expandable tubularmember off of the expansion cone segments 225. Because the outersurfaces, 225 bb and 225 bc, of the expansion cone segments 225 aretapered, the plastic deformation and radial expansion of the expandabletubular member 120 proximate the expansion cone segments is facilitated.Furthermore, in an exemplary embodiment, the continued injection of thefluidic material 275 also pressurizes the annular region 120 aa definedbetween the interior surface of the expandable tubular member 120 andthe exterior surface of the tubular support member 215 that is boundedon the upper end by the packer cup assembly 240 and on the lower end bythe expansion cone segments 225. Furthermore, in an exemplaryembodiment, the pressurization of the annular region 120 aa alsoradially expands the surrounding portion of the expandable tubularmember 120. In this manner, the plastic deformation and radial expansionof the expandable tubular member 120 is enhanced. Furthermore, duringoperation of the apparatus 200, the packer cup assemblies 240 and 250prevent the pressurized fluidic material 275 from passing above andbeyond the packer cup assemblies and thereby define the length of thepressurized annular region 120 aa. In an exemplary embodiment, thepressurization of the annular region 120 aa decreases the operatingpressures required for plastic deformation and radial expansion of theexpandable tubular member 120 by as much as 50% and also reduces theangle of attack of the tapered external surfaces, 225 bb and 225 bc, ofthe expansion cone segments 225.

The radial expansion of the expandable tubular member 120 may thencontinue until the upper end 120 b of the expandable tubular member isradially expanded and plastically deformed along with the overlappingportion of the wellbore casing 110. Because the expansion cone segments225 may be adjustable positioned from an outside diameter less than theinside diameter of the expandable tubular member 120 to an outsidediameter substantially equal to the inside diameter of the pre-existingcasing 110, the resulting wellbore casing, including the casing 110 andthe radially expanded tubular member 120, created by the operation ofthe apparatus 200 may have a single substantially constant insidediameter thereby providing a mono-diameter wellbore casing.

If the expansion cone segments 225 become lodged within the tubularmember 120 during the radial expansion process, the tubular supportmember 215 may be displaced downwardly in the longitudinal direction andthen rotated relative to the drag block assemblies, 235 and 255, therebypositioning the lugs, 215 b and 215 f, within the retaining slots, 255ea and 235 da, respectively, of the J-slots, 255 e and 235 d,respectively. As a result, the expansion cone segments 225 may bedisplaced down the tapered hexagonal portion 215 gb of the expansioncone support body 215 g and away from the end stop 220 therebydecreasing the external diameter of the expansion cone segments. In thismanner, the tubular support member 205, the tubular support member 210,the tubular support member 215, the end stop 220, the expansion conesegments 225, the split ring collar 230, the drag block assembly 235,the pack cup assembly 240, the spacer 245, the packer cup assembly 250,and the drag block assembly 255 may then be removed from the tubularmember 120.

During the radial expansion process, the expansion cone segments 225 maybe raised out of the expanded portion of the tubular member 120 byapplying an upward axial force to the tubular support member 215. In apreferred embodiment, during the radial expansion process, the expansioncone segments 225 are raised at approximately the same rate as thetubular member 120 is expanded in order to keep the tubular memberstationary relative to the new wellbore section 115. In an alternativepreferred embodiment, the expansion cone segments 225 are maintained ina stationary position during the radial expansion process therebyallowing the tubular member 120 to be radially expanded and plasticallydeformed off of the expansion cone segments 225 and into the newwellbore section 115 under the force of gravity and the operatingpressure of the interior of the tubular member 120.

In a preferred embodiment, when the upper end portion of the expandabletubular member 120 and the lower portion of the wellbore casing 110 thatoverlap with one another are plastically deformed and radially expandedby the expansion cone segments 225, the expansion cone segments 225 aredisplaced out of the wellbore 100 by both the operating pressure withinthe interior of the tubular member 120 and a upwardly directed axialforce applied to the tubular support member 205.

In a preferred embodiment, the operating pressure and flow rate of thefluidic material 275 is controllably ramped down when the expansion conesegments 225 reach the upper end portion of the expandable tubularmember 120. In this manner, the sudden release of pressure caused by thecomplete radial expansion and plastic deformation of the expandabletubular member 120 off of the expansion cone segments 225 can beminimized. In a preferred embodiment, the operating pressure is reducedin a substantially linear fashion from 100% to about 10% during the endof the extrusion process beginning when the expansion cone segments 225are within about 5 feet from completion of the extrusion process.

Alternatively, or in combination, the wall thickness of the upper endportion of the expandable tubular member 120 is tapered in order togradually reduce the required operating pressure for plasticallydeforming and radially expanding the upper end portion of the tubularmember. In this manner, shock loading of the apparatus is at leastreduced.

Alternatively, or in combination, a shock absorber is provided in thetubular support member 205 in order to absorb the shock caused by thesudden release of pressure. The shock absorber may comprise, forexample, any conventional commercially available shock absorber, bumpersub, or jars adapted for use in wellbore operations.

Alternatively, or in combination, an expansion cone catching structureis provided in the upper end portion of the expandable tubular member120 in order to catch or at least decelerate the expansion cone segments225.

Alternatively, or in combination, during the radial expansion process,an upward axial force is applied to the tubular support member 215sufficient to plastically deform and radially expand the tubular member120 off of the external surfaces, 225 bb and 225 bc, of the expansioncone segments 225.

Alternatively, or in combination, in order to facilitate thepressurization of the interior 120 a of the expandable tubular member bythe injection of the fluidic materials 275, the region within thewellbore section 115 below the apparatus 200 may be fluidicly sealed offin a convention manner using, for example, a packer.

Once the radial expansion process is completed, the tubular supportmember 205, the tubular support member 210, the tubular support member215, the end stop 220, the expansion cone segments 225, the split ringcollar 230, the drag block assembly 235, the pack cup assembly 240, thespacer 245, the packer cup assembly 250, and the drag block assembly 255are removed from the wellbore 100.

In an alternative embodiment, as illustrated in FIGS. 2 h and 2 i, theJ-slots, 235 d and 255 e, include one or more intermediate retainingslots, 235 db and 255 eb, respectively, that permit the relativelongitudinal displacement of the tubular support member 215 relative tothe drag block assemblies, 235 and 255, to be set at one or moreintermediate stop positions. In this manner, the expansion segments 225may be positioned at one or more intermediate positions on the taperedhexagonal portion 215 gb of the expansion cone support body 215 gthereby permitting the external diameter of the expansion cone segments225 to be adjusted to one or more intermediate sizes. In this manner,the radial expansion and plastic deformation of the expandable tubularmember 120 be provided in different operation stages, each having adifferent expansion diameter. Furthermore, if the expansion conesegments 225 become lodged within the expandable tubular member 120,then the position of the expansion cone segments may be adjusted toprovide a smaller outside diameter and the radial expansion process maybe continued by injecting the fluidic material 275 and/or applying anupward axial force to the tubular support member 215.

Referring to FIGS. 3 and 3 a-3 j, an alternative embodiment of anapparatus 300 for forming a wellbore casing in a subterranean formationwill now be described. The apparatus 300 includes a tubular supportmember 305 defining an internal passage 305 a that is coupled to an endof a tubular coupling 310 defining an internal passage 310 a. The otherend of the tubular coupling 310 is coupled to an end of a tubularsupport member 315 defining an internal passage 315 a that includes afirst flange 315 b having oppositely tapered end-walls, 315 ba and 315bb, a second flange 315 c, a radial passage 315 d, a third flange 315 e,a fourth flange 315 f, a fifth flange 315 g having oppositely taperedend-walls, 315 ga and 315 gb, a fifth flange 315 h, and an expansioncone support body 315 i. The other end of the tubular support member 315is coupled to a tubular end stop 320 that defines a passage 320 a.

As illustrated in FIGS. 3 d and 3 e, the expansion cone support body 315i includes a first end 315 ia, a tapered hexagonal portion 315 ib thatincludes a plurality of T-shaped slots 315 iba provided on each of theexternal faceted surfaces of the tapered hexagonal portion, and a secondend 315 ic. In an exemplary embodiment, the angle of attack of thetapered hexagonal portion 315 ib ranges from about 35 to 50 degrees forreasons to be described.

As illustrated in FIGS. 3, 3 a-3 c, and 3 f-3 h, a plurality ofexpansion cone segments 325 are provided that include first ends 325 athat include T-shaped retaining members 325 aa and second ends 325 bthat include T-shaped retaining members 325 ba that mate with and arereceived within corresponding T-shaped slots 315 iba on the taperedhexagonal portion 315 ib of the expansion cone support body 315 i, firstexternal surfaces 325 bb, second external surfaces 325 bc, and thirdexternal surfaces 325 bd. Thus, in an exemplary embodiment, a total ofsix expansion cone segments 325 are provided that are slidably coupledto corresponding sides of the tapered hexagonal portion 315 ib of theexpansion cone support body 315 i.

In an exemplary embodiment, the widths of the first external surfaces325 bb of the expansion cone segments 325 increase in the direction ofthe second external surfaces 325 bc, the widths of the second externalsurfaces are substantially constant, and the widths of the thirdexternal surfaces 325 bd decrease in the direction of the first ends 325a of the expansion cone segments for reasons to be described. In anexemplary embodiment, the first external surfaces 325 bb of theexpansion cone segments 325 taper upwardly in the direction of thesecond external surfaces 325 bc, the second external surfaces taperupwardly in the direction of the third external surfaces 325 bd, and thethird external surfaces 325 bd taper downwardly in the direction of thefirst ends 325 a of the expansion cone segments for reasons to bedescribed. In an exemplary embodiment, the angle of attack of the taperof the first external surfaces 325 bb of the expansion cone segments 325are greater than the angle of attack of the taper of the second externalsurfaces 325 bc. In an exemplary embodiment, the first and secondexternal surfaces, 325 bb and 325 bc, of the expansion cone segments 325are arcuate such that when the expansion cone segments 325 are displacedin the direction of the end stop 320, the first and second externalsurfaces of the expansion cone segments provide a substantiallycontinuous outer circumferential surface for reasons to be described.

As illustrated in FIG. 3 i, in an exemplary embodiment, the externalsurfaces, 325 bb, 325 bc, and 325 bd, of the second ends 325 b of theexpansion cone segments 325 are adapted to mate with one another inorder to interlock adjacent expansion cone segments.

A split ring collar 330 that defines a passage 330 a for receiving thetubular support member 315 is provided that includes a first end thatincludes plurality of T-shaped slots 330 b for receiving and mating withcorresponding T-shaped retaining members 325 aa of the expansion conesegments 325 and a second end that includes an L-shaped retaining member330 c. In an exemplary embodiment, the split ring collar 330 is aconventional split ring collar commercially available from HalliburtonEnergy Services modified in accordance with the teachings of the presentdisclosure.

A collet assembly 335 is provided that includes a support ring 335 athat defines a passage 335 aa for receiving the tubular support member315 and is coupled to an end of a resilient collet 335 b having upperand lower sets of oppositely tapered shoulders, 335 ba and 335 bb, and,335 bc and 335 bd, respectively, that is positioned proximate the fourthflange 315 g of the tubular support member 315. The other end of thecollet 335 b is coupled to an end of a tubular sleeve 335 c that definesa passage 335 ca. The other end of the tubular sleeve 335 c is coupledto an end of a pin 335 d. The other end of the pin 335 d is coupled to aring 335 e that defines a passage 335 ea for receiving the fifth flange315 h of the tubular support member 315. An end of a tubular couplingsleeve 335 f that defines a passage 335 fa for receiving the tubularsupport member 315 is received within the opening 335 ca of the tubularsleeve 335 c that includes a recess 335 fb for receiving the fifthflange 315 h of the tubular support member 315 and the ring 335 e, and aradial passage 335 fc for receiving the pin 335 d. Another end of thetubular coupling sleeve 335 f includes a passage 335 fd for receivingthe tubular support member 315 and a slot 335 fe for receiving theL-shaped retaining member 330 c of the split ring collar 330. A ring 335g that defines a passage 335 ga for receiving the tubular support member315, a spring 335 h, and a ring 335 i that defines a passage 335 ia forreceiving the tubular support member 315 are also received within therecess 335 fb. The ring 335 g is positioned proximate one end of therecess 335 fb, the ring 335 i is positioned proximate the fifth flange315 h of the tubular support member 315 within the other end of therecess, and the spring 335 h is positioned between the rings.

A first conventional packer cup assembly 340 that defines a passage 340a for receiving the tubular support member 315 includes a first end 340b that mates with the fourth flange 315 f of the tubular support member,a conventional sealing cup 340 c, and a second end 340 d. A tubularspacer 345 that defines a passage 345 a for receiving the tubularsupport member 315 includes a first end 345 b that mates with the.second end 340 d of the first packer cup assembly 340 and a second end345 c. A second conventional packer cup assembly 350 that defines apassage 350 a for receiving the tubular support member 315 includes afirst end 350 b that mates with the second end 345 c of the spacer 345,a conventional sealing cup 350 c, and a second end 350 d that mates withthe third flange 315 e of the tubular support member.

A collet assembly 355 is provided that includes a support ring 355 athat defines a passage 355 aa for receiving the tubular support member315 and is coupled to an end of a resilient collet 355 b having upperand lower sets of oppositely tapered shoulders, 355 ba and 355 bb, and,355 bc and 355 bd, respectively, that is positioned proximate the firstflange 315 b of the tubular support member 315. The other end of thecollet 355 b is coupled to an end of a tubular sleeve 355 c that definesa passage 355 ca. The other end of the tubular sleeve 355 c is coupledto an end of a pin 355 d. The other end of the pin 355 d is coupled to aring 355 e that defines a passage 355 ea for receiving the second flange315 c of the tubular support member 315. An end of a tubular sleeve 355f that defines a passage 355 fa for receiving the tubular support member315 is received within the opening 355 ca of the tubular sleeve 355 cthat includes a recess 355 fb for receiving the second flange 315 c ofthe tubular support member 315 and the ring 355 e, and a radial passage355 fc for receiving the pin 355 d. Another end of the tubular sleeve355 f includes a passage 355 fd for receiving the tubular support member315, a recess 355 fe for receiving an end of the tubular sleeve 355 c,and sealing members 355 ff. A ring 355 g that defines a passage 355 gafor receiving the tubular support member 315 and a spring 355 h are alsoreceived within the recess 355 fb. An end of the ring 355 g ispositioned proximate the second flange 315 c of the tubular supportmember 315 within an end of the recess 355 fb and the other end of thering is positioned an end of the spring 355 h. The other end of thespring 355 h is positioned proximate the other end of the recess 355 fb.

In an exemplary embodiment, during operation of the apparatus 300, asillustrated in FIGS. 3 and 3 a-3 j, the apparatus may be initiallypositioned in the wellbore 100, within the casing 110, with the colletassemblies 335 and 355 positioned in a neutral position in which theradial passage 315 d of the tubular support member 315 is not covered bythe tubular sleeve 355 f and the expansion cone segments 325 are notdriven up the tapered hexagonal portion 315 ib of the expansion conesupport body 315 i of the tubular support member 315 into contact withthe stop member 320. In this manner, fluidic materials within theinterior 315 a of the tubular support member 315 may pass through theradial passage 315 d into the annulus between the apparatus 300 and thecasing 110 thereby preventing over pressurization of the annulus.Furthermore, in this manner, the outside diameter of the expansion conesegments 325 is less than or equal to the outside diameter of the stopmember 320 thereby permitting the apparatus 300 to be displaced withinthe casing 110.

As illustrated in FIGS. 4, and 4 a-4 d, the apparatus 300 may then bepositioned in the tubular member 120. During the insertion of theapparatus into the tubular member 120, the upper end 120 b of thetubular member may impact the tapered shoulders, 335 bb and 355 bb, ofthe collets, 335 b and 355 b, respectively, thereby driving the colletsbackward until the tapered shoulders, 335 bd and 355 bd, of the colletsare positioned proximate the tapered shoulders, 315 ga and 315 ba,respectively, of the tubular support member. As a result, the supportrings, 335 a and 355 a, the collets, 335 b and 355 b, the tubularsleeves, 335 c and 355 c, the pins, 335 d and 355 d, the rings, 335 eand 355 e, and the rings, 335 g and 355 g, of the collet assemblies, 335and 355, respectively, are driven backward, compressing the springs, 335h and 355 h, thereby applying axial biasing forces to the tubularcoupling sleeve 335 f and the tubular sleeve 355 f, respectively. Inthis manner, an axial biasing force is applied to the split ring collar330 and the expansion cone segments 325 that prevents the expansion conesegments from being driven up the tapered hexagonal portion 315 ib ofthe expansion cone support body 315 i of the tubular support member 315into contact with the stop member 320. Thus, the outside diameter of theexpansion cone segments 325 is maintained in a position that is lessthan the inside diameter of the tubular member 120 thereby permittingthe apparatus 300 to be displaced within the tubular member.Furthermore, in this manner, an axial biasing force is applied to thetubular sleeve 355 f thereby preventing the tubular sleeve from coveringthe radial passage 315 d in the tubular support member 315. Thus,fluidic materials within the interior 315 a of the tubular supportmember 315 may pass through the radial passage 315 d into the annulusbetween the apparatus 300 and the tubular member 120 thereby preventingover pressurization of the annulus.

The apparatus 300 may then be at least partially positioned in the openhole section 115 a of the wellbore section 115, beyond the lower end 120c of the tubular member 120. In an exemplary embodiment, that portion ofthe apparatus 300 that includes the stop member 320, the expansion conesegments 325, the split ring collar 330, the collet assembly 335, thepacker cup assembly 340, the spacer 345, the packer cup assembly 350,and the collet assembly 355 is then positioned in the open hole section115 a of the wellbore section 115, beyond the lower end 120 of thetubular member for reasons to be described. Because the collets, 335 band 355 b, are resilient, once the apparatus 300 has been positioned inthe open hole section 115 a of the wellbore section 115, beyond thelower end 120 c of the tubular member 120, the tapered shoulders, 335 baand 355 ba, of the collets may spring outwardly in the radial direction.

The apparatus 300 may then be repositioned at least partially backwithin the tubular member 120. During the re-insertion of the apparatusinto the tubular member 120, the lower end 120 c of the tubular membermay impact the tapered shoulders, 335 ba and 355 ba, of the collets, 335b and 355 b, respectively, thereby driving the collets forward until thetapered shoulders, 335 bc and 355 bc, of the collets are positionedproximate the tapered shoulders, 315 gb and 315 bb, respectively, of thetubular support member 315. As a result, the support rings, 335 a and355 a, the collets, 335 b and 355 b, the tubular sleeves, 335 c and 355c, the pins, 335 d and 355 d, the rings, 335 e and 355 e, the tubularcoupling sleeve 335 f, the tubular sleeve 355 f, the rings, 335 g and355 g, and the ring 335 i of the collet assemblies, 335 and 355,respectively, are driven forward, thereby compressing the springs, 335 hand 355 h, thereby sealing off the radial passage 315 d and driving theexpansion cone segments 325 up the tapered hexagonal portion 315 ib ofthe expansion cone support body 315 i of the tubular support member 315into contact with the stop member 320.

As a result, the outside diameter of the expansion cone segments 325 isnow greater than the inside diameter of expandable tubular member 120thereby permitting the apparatus 300 to be used to radially expand andplastically deform the tubular member, and fluidic materials within theinterior 315 a of the tubular support member 315 may no longer passthrough the radial passage 315 d into the annulus between the apparatus300 and the tubular member thereby permitting the interior of theapparatus to be pressurized.

The apparatus 300 may then be operated to radially expand andplastically deform the tubular member 120 by applying an upward axialforce to the tubular support member 315 and/or by injecting apressurized fluidic material into the tubular support member.

In particular, as illustrated in FIGS. 5 and 5 a-5 d, the expandabletubular member 120 may then be radially expanded using the apparatus 300by injecting a fluidic material 275 into the apparatus through thepassages 305 a, 310 a, 315 a, and 320 a. The injection of the fluidicmaterial 275 may pressurize the interior 120 a of the expandable tubularmember 120. In addition, because the packer cup assemblies, 340 and 350,seal off an annular region 120 aa below the packer cup assembliesbetween the expandable tubular member 120 and the tubular support member315, the injection of the fluidic material 275 may also pressurize theannular region.

The continued injection of the fluidic material 275 may then pressurizethe interior 120 a of the expandable tubular member 120 therebyplastically deforming and radially expanding the expandable tubularmember off of the expansion cone segments 325. Because the outersurfaces, 325 bb and 325 bc, of the expansion cone segments 325 aretapered, the plastic deformation and radial expansion of the expandabletubular member 120 proximate the expansion cone segments is facilitated.Furthermore, in an exemplary embodiment, the continued injection of thefluidic material 275 also pressurizes the annular region 120 aa definedbetween the interior surface of the expandable tubular member 120 andthe exterior surface of the tubular support member 315 that is boundedon the upper end by the packer cup assembly 340 and on the lower end bythe expansion cone segments 325. Furthermore, in an exemplaryembodiment, the pressurization of the annular region 120 aa alsoradially expands at least a portion of the surrounding portion of theexpandable tubular member 120. In this manner, the plastic deformationand radial expansion of the expandable tubular member 120 is enhanced.Furthermore, during operation of the apparatus 300, the packer cupassemblies 340 and 350 prevent the pressurized fluidic material 275 frompassing above and beyond the packer cup assemblies and thereby definethe length of the pressurized annular region 120 aa. In an exemplaryembodiment, the pressurization of the annular region 120 aa decreasesthe operating pressures required for plastic deformation and radialexpansion of the expandable tubular member 120 by as much as 50% andalso reduces the angle of attack of the tapered external surfaces, 325bb and 325 bc, of the expansion cone segments 325.

The radial expansion of the expandable tubular member 120 may thencontinue until the upper end 120 b of the expandable tubular member isradially expanded and plastically deformed along with the overlappingportion of the wellbore casing 110. Because the expansion cone segments325 may be adjustable positioned from an outside diameter less than theinside diameter of the expandable tubular member 120 to an outsidediameter substantially equal to the inside diameter of the pre-existingcasing 110, the resulting wellbore casing, including the casing 110 andthe radially expanded tubular member 120, created by the operation ofthe apparatus 300 may have a single substantially constant insidediameter thereby providing a mono-diameter wellbore casing.

During the radial expansion process, the expansion cone segments 325 maybe raised out of the expanded portion of the tubular member 120 byapplying an upward axial force to the tubular support member 315. In apreferred embodiment, during the radial expansion process, the expansioncone segments 325 are raised at approximately the same rate as thetubular member 120 is expanded in order to keep the tubular memberstationary relative to the new wellbore section 115.

In a preferred embodiment, when the upper end portion of the expandabletubular member 120 and the lower portion of the wellbore casing 110 thatoverlap with one another are plastically deformed and radially expandedby the expansion cone segments 325, the expansion cone segments aredisplaced out of the wellbore 100 by both the operating pressure withinthe interior of the tubular member 120 and a upwardly directed axialforce applied to the tubular support member 305.

In a preferred embodiment, the operating pressure and flow rate of thefluidic material 275 is controllably ramped down when the expansion conesegments 325 reach the upper end portion of the expandable tubularmember 120. In this manner, the sudden release of pressure caused by thecomplete radial expansion and plastic deformation of the expandabletubular member 120 off of the expansion cone segments 325 can beminimized. In a preferred embodiment, the operating pressure is reducedin a substantially linear fashion from 100% to about 10% during the endof the extrusion process beginning when the expansion cone segments 325are within about 5 feet from completion of the extrusion process.

Alternatively, or in combination, the wall thickness of the upper endportion of the expandable tubular member 120 is tapered in order togradually reduce the required operating pressure for plasticallydeforming and radially expanding the upper end portion of the tubularmember. In this manner, shock loading of the apparatus is at leastreduced.

Alternatively, or in combination, a shock absorber is provided in thetubular support member 305 in order to absorb the shock caused by thesudden release of pressure. The shock absorber may comprise, forexample, any conventional commercially available shock absorber, bumpersub, or jars adapted for use in wellbore operations.

Alternatively, or in combination, an expansion cone catching structureis provided in the upper end portion of the expandable tubular member120 in order to catch or at least decelerate the expansion cone segments325.

Alternatively, or in combination, during the radial expansion process,an upward axial force is applied to the tubular support member 315sufficient to plastically deform and radially expand the tubular member120 off of the external surfaces, 225 bb and 225 bc, of the expansioncone segments 325.

Alternatively, or in combination, in order to facilitate thepressurization of the interior 120 a of the expandable tubular member bythe injection of the fluidic materials 275, the region within thewellbore section 115 below the apparatus 300 may be fluidicly sealed offin a convention manner using, for example, a packer.

Once the radial expansion process is completed, the tubular supportmember 305, the tubular support member 310, the tubular support member315, the end stop 320, the expansion cone segments 325, the split ringcollar 330, the collet assembly 335, the packer cup assembly 340, thespacer 345, the packer cup assembly 350, and the collet assembly 355 areremoved from the wellbores 100 and 115.

Referring to FIGS. 6 and 6 a-6 k, an alternative embodiment of anapparatus 400 for forming a wellbore casing in a subterranean formationwill now be described. The apparatus 400 includes a tubular supportmember 405 defining an internal passage 405 a that is coupled to an endof a tubular coupling 410 defining an internal passage 410 a. The otherend of the tubular coupling 410 is coupled to an end of a tubularsupport member 415 defining an internal passage 415 a that includes afirst flange 415 b, a first radial passage 415 c, a second radialpassage 415 d, a second flange 415 e, a stepped flange 415 f, a thirdflange 415 g, a fourth flange 415 h, a fifth flange 415 i, and anexpansion cone body 415 j. The other end of the tubular support member415 is coupled to a tubular end stop 420 that defines a passage 420 a.

As illustrated in FIGS. 6 eand 6 f, the expansion cone support body 415j includes a first end 415 ja, a tapered hexagonal portion 415 jb thatincludes a plurality of T-shaped slots 415 jba provided on each of theexternal faceted surfaces of the tapered hexagonal portion, and a secondend 415 jc. In an exemplary embodiment, the angle of attack of thetapered hexagonal portion 415 jb ranges from about 35 to 50 degrees forreasons to be described.

As illustrated in FIGS. 6, 6 a-6 d, and 6 g-6 i, a plurality ofexpansion cone segments 425 are provided that include first ends 425 athat include T-shaped retaining members 425 aa and second ends 425 bthat include T-shaped retaining members 425 ba that mate with and arereceived within corresponding T-shaped slots 415 jba on the taperedhexagonal portion 415 jb of the expansion cone support body 415 j, firstexternal surfaces 425 bb, second external surfaces 425 bc, and thirdexternal surfaces 425 bd. Thus, in an exemplary embodiment, a total ofsix expansion cone segments 425 are provided that are slidably coupledto corresponding sides of the tapered hexagonal portion 415 jb of theexpansion cone support body 415 j.

In an exemplary embodiment, the widths of the first external surfaces425 bb of the expansion cone segments 425 increase in the direction ofthe second external surfaces 425 bc, the widths of the second externalsurfaces are substantially constant, and the widths of the thirdexternal surfaces 425 bd decrease in the direction of the first ends 425a of the expansion cone segments for reasons to be described. In anexemplary embodiment, the first external surfaces 425 bb of theexpansion cone segments 425 taper upwardly in the direction of thesecond external surfaces 425 bc, the second external surfaces taperupwardly in the direction of the third external surfaces 425 bd, and thethird external surfaces 425 bd taper downwardly in the direction of thefirst ends 425 a of the expansion cone segments for reasons to bedescribed. In an exemplary embodiment, the angle of attack of the taperof the first external surfaces 425 bb of the expansion cone segments 425are greater than the angle of attack of the taper of the second externalsurfaces 425 bc. In an exemplary embodiment, the first and secondexternal surfaces, 425 bb and 425 bc, of the expansion cone segments 425are arcuate such that when the expansion cone segments 425 are displacedin the direction of the end stop 420, the first and second externalsurfaces of the expansion cone segments provide a substantiallycontinuous outer circumferential surface for reasons to be described.

As illustrated in FIG. 6 j, in an exemplary embodiment, the externalsurfaces, 425 bb, 425 bc, and 425 bd, of the second ends 425 b of theexpansion cone segments 425 are adapted to mate with one another inorder to interlock adjacent expansion cone segments.

A split ring collar 430 that defines a passage 430 a for receiving thetubular support member 415 is provided that includes a first end thatincludes plurality of T-shaped slots 430 b for receiving and mating withcorresponding T-shaped retaining members 425 aa of the expansion conesegments 425 and a second end that includes an L-shaped retaining member430 c. In an exemplary embodiment, the split ring collar 430 is aconventional split ring collar commercially available from HalliburtonEnergy Services modified in accordance with the teachings of the presentdisclosure.

A dog assembly 435 is provided that includes a tubular sleeve 435 a thatdefines a passage 435 aa for receiving the tubular support member 415that includes a first end that includes a slot 435 ab for receiving andmating with the L-shaped retaining member 430 c of the split ring collar430, a radial passage 435 ac, and a recess 435 ad for receiving thefifth flange 415 a of the tubular support member 415. A second end ofthe tubular sleeve 435 a includes a flange 435 ae that mates with thefourth flange 415 h of the tubular support member 415. A retaining ring435 b that defines a passage 435 ba for receiving the fifth flange 415 iis received within the recess 435 ad of the tubular sleeve 435 a and iscoupled to an end of a load transfer pin 435 c. The opposite end of theload transfer pin 435 c is received within the radial passage 435 ac ofthe tubular sleeve 435 a and is coupled to an end of a tubular sleeve435 d that includes a recess 435 da at a first end for receiving thetubular sleeve 435 a, and a radial opening 435 dc for receiving aconventional resilient dog 435 e. A spring 435 f and a ring 435 g thatdefines a passage 435 ga for receiving the tubular support member 415are received within the recess 435 ad of the tubular sleeve 435 abetween a first end of the recess and the fifth flange 415 i of thetubular support member.

A first conventional packer cup assembly 440 that defines a passage 440a for receiving the tubular support member 415 includes a first end 440b that mates with the fourth flange 415 g of the tubular support member,a conventional sealing cup 440 c, and a second end 440 d. A tubularspacer 445 that defines a passage 445 a for receiving the tubularsupport member 415 includes a first end 445 b that mates with the secondend 440 d of the first packer cup assembly 440 and a second end 445 c. Asecond conventional packer cup assembly 450 that defines a passage 450 afor receiving the tubular support member 415 includes a first end 450 bthat mates with the second end 445 c of the spacer 445, a conventionalsealing cup 450 c, and a second end 450 d that mates with the steppedflange 415 f of the tubular support member.

A dog assembly 455 is provided that includes a tubular sleeve 455 a thatdefines a passage 455 aa for receiving the tubular support member 415. Afirst end of the tubular sleeve 455 a includes a radial opening 455 abfor receiving a conventional resilient dog 455 b. A second end of thetubular sleeve 455 a includes a recess 455 ac and is coupled to an endof a load transfer pin 455 c. The opposite end of the load transfer pin455 c is coupled to a retaining ring 455 d that defines a passage 455 dafor receiving the tubular support member 415. A tubular sleeve 455 e isreceived within the recess 455 ac of the tubular sleeve 455 a thatdefines a passage 455 ea for receiving the tubular support member 415and includes a first end that includes a radial passage 455 eb forreceiving the load transfer pin 455 c and a recess 455 ec for receivinga spring 455 f. A ring 455 g that defines a passage 455 ga for receivingthe tubular support member 415 is further received within the recess 455ec of the tubular sleeve 455 e between the spring 455 f and the secondflange 415 e of the tubular support member 415. A second end of thetubular sleeve 455 e includes a radial passage 455 ed, sealing members,455 ef and 455 eg, and a recess 455 eh that mates with the first flange415 b of the tubular support member 415.

In an exemplary embodiment, during operation of the apparatus 400, asillustrated in FIGS. 6 and 6 a-6 k, the apparatus may be initiallypositioned in the wellbore 100, within the casing 110, with the dogassemblies 435 and 455 positioned in a neutral position in which theradial passage 415 d of the tubular support member 415 is fluidiclycoupled to the radial passage 455 ed of the dog assembly 455 and theexpansion cone segments 425 are not driven up the tapered hexagonalportion 415 jb of the expansion cone support body 415 j of the tubularsupport member 415 into contact with the stop member 320. In thismanner, fluidic materials within the interior 415 a of the tubularsupport member 415 may pass through the radial passages, 415 d and 455ed, into the annulus between the apparatus 400 and the casing 110thereby preventing over pressurization of the annulus. Furthermore, inthis manner, the outside diameter of the expansion cone segments 425 isless than or equal to the outside diameter of the stop member 420thereby permitting the apparatus 400 to be displaced within the casing110.

As illustrated in FIGS. 7, and 7 a-7 c, the apparatus 400 may then bepositioned in the tubular member 120. During the insertion of theapparatus into the tubular member 120, the upper end 120 b of thetubular member may impact the ends of the resilient dogs, 435 e and 455b, of the dog assemblies, 435 and 455, respectively, thereby driving theresilient dogs, 435 e and 455 b, backwards off of and adjacent to oneside of the flanges, 415 h and 415 f, respectively. As a result of thebackward axial displacement of the resilient dog 435 e, the tubularsleeve 435 d, the pin 435 c, the retaining ring 435 b, and the ring 435g of the dog assembly 435 are driven backward thereby compressing thespring 435 f and applying an axial biasing force to the tubular sleeve435 a that prevents the expansion cone segments 425 from being displacedtoward the end stop 420. As a result of the backward axial displacementof the resilient dog 455 b, the tubular sleeve 455 a, the pin 455 c, theretaining ring 455 d, and the ring 455 g of the dog assembly 455 aredriven backward thereby compressing the spring 455 f and applying anaxial biasing force to the tubular sleeve 455 e that prevents the radialpassages, 415 d and 455 ed from being fluidicly decoupled.

The apparatus 400 may then be at least partially positioned in the openhole section 115 a of the wellbore section 115, beyond the lower end 120c of the tubular member 120. In an exemplary embodiment, that portion ofthe apparatus 400 that includes the stop member 420, the expansion conesegments 425, the split ring collar 430, the dog assembly 435, thepacker cup assembly 440, the spacer 445, the packer cup assembly 450,and the dog assembly 455 is then positioned in the open hole section 115a of the wellbore section 115, beyond the lower end 120 of the tubularmember for reasons to be described. Because the dogs, 435 e and 455 b,of the dog assemblies, 435 and 455, respectively, are resilient, oncethe apparatus 400 has been positioned in the open hole section 115 a ofthe wellbore section 115, beyond the lower end 120 c of the tubularmember 120, the resilient dogs, 435 e and 455 b, of the dog assembliesmay spring outwardly in the radial direction.

The apparatus 400 may then be repositioned at least partially backwithin the tubular member 120. During the re-insertion of the apparatusinto the tubular member 120, the lower end 120 c of the tubular membermay impact the ends of the resilient dogs, 435 e and 455 b, of the dogassemblies, 435 and 455, respectively, thereby driving the resilientdogs forward until the resilient dogs are positioned beyond and adjacentto the other side of the flanges, 415 h and 415 f, of the tubularsupport member 415.

As a result, of the forward axial displacement of the resilient dog 435e, the tubular sleeve 435 a, the retaining ring 435 b, the pin 435 c,the tubular sleeve 435 d, the spring 435 f, and the ring 435 g of thedog assembly 435 are displaced in the forward axial direction therebyalso displacing the split ring collar 430 and the expansion conesegments 425 in the forward axial direction. As a result, the expansioncone segments 425 are driven up the tapered hexagonal portion 415 jb ofthe expansion cone support body 415 j of the tubular support member 415into contact with the stop member 320.

As a result of the forward axial displacement of the resilient dog 455b, the tubular sleeve 455 a, the pin 455 c, the retaining ring 455 d,the tubular sleeve 455 e, the spring 455 f, and the ring 455 g of thedog assembly 455 are driven forward in the axial direction therebyfluidicly decoupling the radial passages, 415 d and 455 ed, andfluidicly coupling the radial passages 415 c and 415 d. As a resultfluidic materials within the tubular support member 415 may not passinto the annulus between the tubular support member and the tubularmember 120.

As a result of the forward axial displacement of the resilient dog 435e, the outside diameter of the expansion cone segments 425 is nowgreater than the inside diameter of expandable tubular member 120thereby permitting the apparatus 400 to be used to radially expand andplastically deform the tubular member, and fluidic materials within theinterior 415 a of the tubular support member 415 may no longer passthrough the radial passages, 415 d and 455 ed, into the annulus betweenthe apparatus 400 and the tubular member thereby permitting the interiorof the apparatus to be pressurized.

The apparatus 400 may then be operated to radially expand andplastically deform the tubular member 120 by applying an upward axialforce to the tubular support member 415 and/or by injecting apressurized fluidic material into the tubular support member.

In particular, as illustrated in FIGS. 8 and 8 a-8 d, the expandabletubular member 120 may then be radially expanded using the apparatus 400by injecting a fluidic material 275 into the apparatus through thepassages 405 a, 310 a, 415 a, and 420 a. The injection of the fluidicmaterial 275 may pressurize the interior 120 a of the expandable tubularmember 120. In addition, because the packer cup assemblies, 440 and 450,seal off an annular region 120 aa below the packer cup assembliesbetween the expandable tubular member 120 and the tubular support member415, the injection of the fluidic material 275 may also pressurize theannular region.

The continued injection of the fluidic material 275 may then pressurizethe interior 120 a of the expandable tubular member 120 therebyplastically deforming and radially expanding the expandable tubularmember off of the expansion cone segments 425. Because the outersurfaces, 425 bb and 425 bc, of the expansion cone segments 425 aretapered, the plastic deformation and radial expansion of the expandabletubular member 120 proximate the expansion cone segments is facilitated.Furthermore, in an exemplary embodiment, the continued injection of thefluidic material 275 also pressurizes the annular region 120 aa definedbetween the interior surface of the expandable tubular member 120 andthe exterior surface of the tubular support member 415 that is boundedon the upper end by the packer cup assembly 440 and on the lower end bythe expansion cone segments 425. Furthermore, in an exemplaryembodiment, the pressurization of the annular region 120 aa alsoradially expands at least a portion of the surrounding portion of theexpandable tubular member 120. In this manner, the plastic deformationand radial expansion of the expandable tubular member 120 is enhanced.Furthermore, during operation of the apparatus 300, the packer cupassemblies 440 and 450 prevent the pressurized fluidic material 275 frompassing above and beyond the packer cup assemblies and thereby definethe length of the pressurized annular region 120 aa. In an exemplaryembodiment, the pressurization of the annular region 120 aa decreasesthe operating pressures required for plastic deformation and radialexpansion of the expandable tubular member 120 by as much as 50% andalso reduces the angle of attack of the tapered external surfaces, 425bb and 425 bc, of the expansion cone segments 425.

The radial expansion of the expandable tubular member 120 may thencontinue until the upper end 120 b of the expandable tubular member isradially expanded and plastically deformed along with the overlappingportion of the wellbore casing 110. Because the expansion cone segments425 may be adjustably positioned from an outside diameter less than theinside diameter of the expandable tubular member 120 to an outsidediameter substantially equal to the inside diameter of the pre-existingcasing 110, the resulting wellbore casing, including the casing 110 andthe radially expanded tubular member 120, created by the operation ofthe apparatus 400 may have a single substantially constant insidediameter thereby providing a mono-diameter wellbore casing.

During the radial expansion process, the expansion cone segments 425 maybe raised out of the expanded portion of the tubular member 120 byapplying an upward axial force to the tubular support member 415. In apreferred embodiment, during the radial expansion process, the expansioncone segments 425 are raised at approximately the same rate as thetubular member 120 is expanded in order to keep the tubular memberstationary relative to the new wellbore section 115.

In a preferred embodiment, when the upper end portion of the expandabletubular member 120 and the lower portion of the wellbore casing 110 thatoverlap with one another are plastically deformed and radially expandedby the expansion cone segments 425, the expansion cone segments aredisplaced out of the wellbore 100 by both the operating pressure withinthe interior of the tubular member 120 and a upwardly directed axialforce applied to the tubular support member 405.

In a preferred embodiment, the operating pressure and flow rate of thefluidic material 275 is controllably ramped down when the expansion conesegments 425 reach the upper end portion of the expandable tubularmember 120. In this manner, the sudden release of pressure caused by thecomplete radial expansion and plastic deformation of the expandabletubular member 120 off of the expansion cone segments 425 can beminimized. In a preferred embodiment, the operating pressure is reducedin a substantially linear fashion from 100% to about 10% during the endof the extrusion process beginning when the expansion cone segments 425are within about 5 feet from completion of the extrusion process.

Alternatively, or in combination, the wall thickness of the upper endportion of the expandable tubular member 120 is tapered in order togradually reduce the required operating pressure for plasticallydeforming and radially expanding the upper end portion of the tubularmember. In this manner, shock loading of the apparatus is at leastreduced.

Alternatively, or in combination, a shock absorber is provided in thetubular support member 405 in order to absorb the shock caused by thesudden release of pressure. The shock absorber may comprise, forexample, any conventional commercially available shock absorber, bumpersub, or jars adapted for use in wellbore operations.

Alternatively, or in combination, an expansion cone catching structureis provided in the upper end portion of the expandable tubular member120 in order to catch or at least decelerate the expansion cone segments425.

Alternatively, or in combination, during the radial expansion process,an upward axial force is applied to the tubular support member 415sufficient to plastically deform and radially expand the tubular member120 off of the external surfaces, 225 bb and 225 bc, of the expansioncone segments 425.

Alternatively, or in combination, in order to facilitate thepressurization of the interior 120 a of the expandable tubular member bythe injection of the fluidic materials 275, the region within thewellbore section 115 below the apparatus 400 may be fluidicly sealed offin a convention manner using, for example, a packer.

Once the radial expansion process is completed, the tubular supportmember 405, the tubular support member 410, the tubular support member415, the end stop 420, the expansion cone segments 425, the split ringcollar 430, the dog assembly 435, the packer cup assembly 440, thespacer 445, the packer cup assembly 450, and the dog assembly 455 areremoved from the wellbores 100 and 115.

Referring now to FIGS. 9, 9 a, 10 and 10 a, an embodiment of anadjustable expansion cone assembly 500 will be described. The assembly500 includes a tubular support member 505 that defines a passage 505 aand includes a flange 505 b, an expansion cone support flange assembly505 c, and an end stop 505 d. The expansion cone support flange assembly505 c includes a tubular body 505 ca and a plurality of equally spacedapart expansion cone segment support members 505 cb that extendoutwardly from the tubular body in the radial direction that eachinclude identical bases 505 cba and extensions 505 cbb. The supportmembers 505 cb further include first sections 505 cbc having arcuateconical outer surfaces and second sections 505 cbd having arcuatecylindrical outer surfaces for reasons to be described.

An expansion cone segment assembly 510 is provided that includes atubular support 510 a defining a passage 510 aa for receiving thetubular support member 505 and a slot 510 ab. A plurality of spacedapart and substantially identical resilient expansion cone segmentcollets 510 b extend from the tubular support 510 a in the axialdirection that include expansion cone segments 510 ba extendingtherefrom in the axial direction. Each of the expansion cone segments510 ba further include arcuate conical expansion surfaces 510 baa forradially expanding an expandable tubular member.

A split ring collar 515 is provided that defines a passage 515 a forreceiving the tubular support member 505 that includes an L-shapedretaining member 515 b at one end for mating with the slot 510 ab of thetubular support 510 a of the expansion cone segment assembly 510.Another end of the split ring collar 515 includes an L-shaped retainingmember 515 c. A tubular sleeve 520 is provided that defines a passage520 a for receiving the tubular support member 505 that includes a slot520 b for receiving the L-shaped retaining member 515 c of the splitring collar 515.

During operation of the assembly 500, as illustrated in FIGS. 9 and 9 a,in an unexpanded position, the expansion cone segments 510 ba of theexpansion cone segment assembly 510 are positioned adjacent to the baseof the conical section 505 cbc of the expansion cone segment supportmembers 505 cb with the outside diameter of the expansion cone segmentsless than or equal to the maximum outside diameter of the assembly. Asillustrated in FIGS. 10 and 10 a, the assembly 500 may then be expandedby displacing the tubular sleeve 520, the split ring collar 515, and theexpansion cone segment assembly 510 in the axial direction towards theexpansion cone segment support members 505 cb. As a result, theexpansion cone segments 510 ba are driven up the conical section 505 cbcof the expansion cone segment support members 505 cb and then onto thecylindrical section 505 cbd of the expansion cone segment supportmembers until the expansion cone segments impact the end stop 505 d. Inthis manner, the outside diameter of the expansion segments 510 ba isgreater than the maximum diameter of the remaining components of theassembly 500. Furthermore, the conical outer surfaces 510 baa of theexpansion cone segments 510 ba may now be used to radially expand atubular member. Note that the extensions 505 cbb of the expansion conesegment support members 505 cb provide support in the circumferentialdirection to the adjacent expansion cone segments 510 ba. In anexemplary embodiment, the outer conical surfaces 510 baa of theexpansion cone segments 510 ba in the expanded position of the assembly500 provide a substantially continuous outer conical surfaces in thecircumferential direction.

The assembly 500 may then be returned to the unexpanded position bydisplacing the tubular sleeve 520, the split ring collar 515, and theexpansion cone segment assembly 510 in the axial direction away from theexpansion cone segment support members 505 cb. As a result, theexpansion cone segments 510 ba are displaced off of the cylindricalsection 505 cbd and the conical section 505 cbc of the expansion conesegment support members 505 cb. Because the collets 510 b of theexpansion cone segment assembly 510 are resilient, the expansionsegments 510 ba are thereby returned to a position in which the outsidediameter of the expansion cone segments is less than or equal to themaximum diameter of the remaining components of the assembly 500.

In several alternative embodiments, the assembly 500 is incorporatedinto the assemblies 200, 300 and/or 400.

Referring now to FIGS. 11, 11 a, 12 and 12 a, an embodiment of anadjustable expansion cone assembly 600 will be described. The assembly600 includes a tubular support member 605 that defines a passage 605 aand includes an expansion cone support flange assembly 605 b, and an endstop 605 c. The expansion cone support flange assembly 605 b includes atubular body 605 ba and a plurality of equally spaced apart expansioncone segment substantially identical support members 605 bb that extendoutwardly from the tubular body in the radial direction. The supportmembers 605 bb further include first sections 605 bba having arcuatecylindrical outer surfaces, second sections 605 bbb having arcuateconical outer surfaces, and third sections 605 bbc having arcuatecylindrical outer surfaces for reasons to be described.

An expansion cone segment assembly 610 is provided that includes atubular support 610 a defining a passage 610 aa for receiving thetubular support member 605 and a slot 610 ab. A plurality of spacedapart and substantially identical resilient expansion cone segmentcollets 610 b extend from the tubular support 610 a in the axialdirection that include expansion cone segments 610 ba extendingtherefrom in the axial direction. Each of the expansion cone segments610 ba further include arcuate conical expansion surfaces 610 baa forradially expanding an expandable tubular member.

A split ring collar 615 is provided that defines a passage 615 a forreceiving the tubular support member 605 that includes an L-shapedretaining member 615 b at one end for mating with the slot 610 ab of thetubular support 610 a of the expansion cone segment assembly 610.Another end of the split ring collar 615 includes an L-shaped retainingmember 615 c. A tubular sleeve 620 is provided that defines a passage620 a for receiving the tubular support member 605 that includes a slot620 b for receiving the L-shaped retaining member 615 c of the splitring collar 615.

During operation of the assembly 600, as illustrated in FIGS. 11 and 11a, in an unexpanded position, the expansion cone segments 610 ba of theexpansion cone segment assembly 610 are positioned on the cylindricalsection 605 bba, adjacent to the base of the conical section 605 bbb, ofthe expansion cone segment support members 605 bb with the outsidediameter of the expansion cone segments less than or equal to themaximum outside diameter of the assembly. As illustrated in FIGS. 12 and12 a, the assembly 600 may then be expanded by displacing the tubularsleeve 620, the split ring collar 615, and the expansion cone segmentassembly 610 in the axial direction towards the expansion cone segmentsupport members 605 bb. As a result, the expansion cone segments 610 baare driven up the conical section 605 bbb of the expansion cone segmentsupport members 605 bb and then onto the cylindrical section 605 bbc ofthe expansion cone segment support members until the expansion conesegments impact the end stop 605 c. In this manner, the outside diameterof the expansion segments 610 ba is greater than the maximum diameter ofthe remaining components of the assembly 600. Furthermore, the conicalouter surfaces 610 baa of the expansion cone segments 610 ba may now beused to radially expand a tubular member. In an exemplary embodiment,the outer conical surfaces 610 baa of the expansion cone segments 610 bain the expanded position of the assembly 600 provide a substantiallycontinuous outer conical surfaces in the circumferential direction.

The assembly 600 may then be returned to the unexpanded position bydisplacing the tubular sleeve 620, the split ring collar 615, and theexpansion cone segment assembly 610 in the axial direction away from theexpansion cone segment support members 605 bb. As a result, theexpansion cone segments 610 ba are displaced off of the cylindricalsection 605 bbc and the conical section 605 bbb and back onto thecylindrical section 605 bba of the expansion cone segment supportmembers 605 bb. Because the collets 610 b of the expansion cone segmentassembly 610 are resilient, the expansion segments 610 ba are therebyreturned to a position in which the outside diameter of the expansioncone segments is less than or equal to the maximum diameter of theremaining components of the assembly 600.

In several alternative embodiments, the assembly 600 is incorporatedinto the assemblies 200, 300 and/or 400.

Referring now to FIGS. 13, 13 a, 13 b, 13 c, 14 and 14 a, an embodimentof an adjustable expansion cone assembly 700 will be described. Theassembly 700 includes a tubular support member 705 that defines apassage 705 a and includes an expansion cone support flange assembly 705b, and an end stop 705 c. The expansion cone support flange assembly 705b includes a tubular body 705 ba and a plurality of equally spaced apartexpansion cone segment substantially identical support members 705 bbthat extend outwardly from the tubular body in the radial direction. Thesupport members 705 bb further include first sections 705 bba havingarcuate cylindrical outer surfaces, second sections 705 bbb havingarcuate conical outer surfaces, and third sections 705 bbc havingarcuate cylindrical outer surfaces for reasons to be described.

An expansion cone segment assembly 710 is provided that includes a firsttubular support 710 a defining a passage 710 aa for receiving thetubular support member 705 that includes a slot 710 ab and a secondtubular support 710 b defining a passage 710 ba for receiving thetubular support member 705 that includes a plurality of spaced apart andsubstantially identical axial slots 710 bb. A plurality of spaced apartand substantially identical resilient expansion cone segment collets 710ac extend from the first tubular support 710 a in the axial directionand are received within corresponding ones of the axial slots 710 bb inthe second tubular support 710 b that include substantially identicalexpansion cone segments 710 aca extending therefrom in the axialdirection. A plurality of spaced apart and substantially identicalresilient expansion cone segment collets 710 bc extend from the secondtubular support 710 b in the axial direction that are interleaved andoverlap with the expansion cone segment collets 710 ac and that includesubstantially identical expansion cone segments 710 bca extendingtherefrom in the axial direction. Each of the expansion cone segments,710 aca and 710 bca, further include arcuate conical expansion surfaces,710 acaa and 710 bcaa, respectively, for radially expanding anexpandable tubular member. A plurality of pins 715 a-715 d couple theexpansion cone segment collets 710 ac to the second tubular support 710b.

A split ring collar 720 is provided that defines a passage 720 a forreceiving the tubular support member 705 that includes an L-shapedretaining member 720 b at one end for mating with the slot 710 ab of thefirst tubular support 710 a of the expansion cone segment assembly 710.Another end of the split ring collar 720 includes an L-shaped retainingmember 720 c. A tubular sleeve 725 is provided that defines a passage725 a for receiving the tubular support member 705 that includes a slot725 b for receiving the L-shaped retaining member 720 c of the splitring collar 720.

During operation of the assembly 700, as illustrated in FIGS. 13, 13 a,13 b, and 13 c, in an unexpanded position, the expansion cone segments710 aca of the expansion cone segment assembly 710 overlap with and arepositioned over the expansion cone segments 710 bca of the expansioncone segment assembly, adjacent to the base of the conical section 705bbb, of the expansion cone segment support members 705 bb with theoutside diameter of the expansion cone segments less than or equal tothe maximum outside diameter of the assembly. As illustrated in FIGS. 14and 14 a, the assembly 700 may then be expanded by displacing thetubular sleeve 725, the split ring collar 720, and the expansion conesegment assembly 710 in the axial direction towards the expansion conesegment support members 705 bb. As a result, the expansion conesegments, 710 aca and 710 bca, are driven up the conical section 705 bbbof the expansion cone segment support members 705 bb and then onto thecylindrical section 705 bbc of the expansion cone segment supportmembers until the expansion cone segments impact the end stop 705 c. Inthis manner, the outside diameter of the expansion segments, 710 aca and710 bca, is greater than the maximum diameter of the remainingcomponents of the assembly 700. Furthermore, the conical outer surfaces,710 acaa and 710 bcaa, of the expansion cone segments, 710 aca and 710bca, respectively, may now be used to radially expand a tubular member.In an exemplary embodiment, the outer conical surfaces, 710 acaa and 710bcaa, of the expansion cone segments, 710 aca and 710 bca, respectively,in the expanded position of the assembly 700 provide a substantiallycontinuous outer conical surfaces in the circumferential direction.

The assembly 700 may then be returned to the unexpanded position bydisplacing the tubular sleeve 720, the split ring collar 715, and theexpansion cone segment assembly 710 in the axial direction away from theexpansion cone segment support members 705 bb. As a result, theexpansion cone segments, 710 aca and 710 bca, are displaced off of thecylindrical section 705 bbc and the conical section 705 bbb and backonto the cylindrical section 705 bba of the expansion cone segmentsupport members 705 bb. Because the collets, 710 ac and 710 bc, of theexpansion cone segment assembly 710 are resilient, the expansionsegments, 710 aca and 710 bca, are thereby returned to a position inwhich the outside diameter of the expansion cone segments is less thanor equal to the maximum diameter of the remaining components of theassembly 700.

In several alternative embodiments, the assembly 700 is incorporatedinto the assemblies 200, 300 and/or 400.

Referring to FIGS. 15 and 15 a-15 j, an alternative embodiment of anapparatus 800 for forming a wellbore casing in a subterranean formationwill now be described. The apparatus 800 includes a tubular supportmember 805 defining an internal passage 805 a that is coupled to an endof a tubular coupling 810 defining an internal passage 810 a. The otherend of the tubular coupling 810 is coupled to an end of a tubularsupport member 815 defining an internal passage 815 a having a throatpassage 815 aa that includes a first radial passage 815 b, a firstflange 815 c having a second radial passage 815 d, a second flange 815 ehaving opposite shoulders, 815 ea and 815 eb, a third flange 815 f, andan expansion cone support body 815 g. The other end of the tubularsupport member 815 is coupled to a tubular end stop 820 that defines apassage 820 a.

As illustrated in FIGS. 15 d and 15 e, the expansion cone support body815 g includes a first end 815 ga, a tapered hexagonal portion 815 gbthat includes a plurality of T-shaped slots 815 gba provided on each ofthe external faceted surfaces of the tapered hexagonal portion, and asecond end 815 gc. In an exemplary embodiment, the angle of attack ofthe tapered hexagonal portion 815 gb ranges from about 35 to 50 degreesfor reasons to be described.

As illustrated in FIGS. 15, 15 a-15 c, and 15 f-15 j, a plurality ofexpansion cone segments 825 are provided that include first ends 825 athat include T-shaped retaining members 825 aa and second ends 825 bthat include T-shaped retaining members 825 ba that mate with and arereceived within corresponding T-shaped slots 815 gba on the taperedhexagonal portion 815 gb of the expansion cone support body 815 g, firstexternal surfaces 825 bb, second external surfaces 825 bc, and thirdexternal surfaces 825 bd. Thus, in an exemplary embodiment, a total ofsix expansion cone segments 825 are provided that are slidably coupledto corresponding sides of the tapered hexagonal portion 815 gb of theexpansion cone support body 815 g.

In an exemplary embodiment, the widths of the first external surfaces825 bb of the expansion cone segments 825 increase in the direction ofthe second external surfaces 825 bc, the widths of the second externalsurfaces are substantially constant, and the widths of the thirdexternal surfaces 825 bd decrease in the direction of the first ends 825a of the expansion cone segments for reasons to be described. In anexemplary embodiment, the first external surfaces 825 bb of theexpansion cone segments 825 taper upwardly in the direction of thesecond external surfaces 825 bc, the second external surfaces taperupwardly in the direction of the third external surfaces 825 bd, and thethird external surfaces 825 bd taper downwardly in the direction of thefirst ends 825 a of the expansion cone segments for reasons to bedescribed. In an exemplary embodiment, the angle of attack of the taperof the first external surfaces 825 bb of the expansion cone segments 825are greater than the angle of attack of the taper of the second externalsurfaces 825 bc. In an exemplary embodiment, the first and secondexternal surfaces, 825 bb and 825 bc, of the expansion cone segments 825are arcuate such that when the expansion cone segments 825 are displacedin the direction of the end stop 420, the first and second externalsurfaces of the expansion cone segments provide a substantiallycontinuous outer circumferential surface for reasons to be described.

As illustrated in FIG. 15 i, in an exemplary embodiment, the externalsurfaces, 825 bb, 825 bc, and 825 bd, of the second ends 825 b of theexpansion cone segments 825 are adapted to mate with one another inorder to interlock adjacent expansion cone segments.

A split ring collar 830 that defines a passage 830 a for receiving thetubular support member 815 is provided that includes a first end thatincludes plurality of T-shaped slots 830 b for receiving and mating withcorresponding T-shaped retaining members 825 aa of the expansion conesegments 825 and a second end that includes an L-shaped retaining member830 c. In an exemplary embodiment, the split ring collar 830 is aconventional split ring collar commercially available from HalliburtonEnergy Services modified in accordance with the teachings of the presentdisclosure.

A dog assembly 835 is provided that includes a tubular sleeve 835 a thatdefines a passage 835 aa for receiving the tubular support member 815and includes a slot 835 ab for receiving and mating with the L-shapedretaining member 830 c of the split ring collar 830, a counterbore 835ac, and a radial passage 835 ad. An end of a load transfer pin 835 bpasses through the radial passage 835 ad and is coupled to a retainingring 835 c that defines a passage 835 ca for receiving the flange 815 fof the tubular support member 815 and is received within the counterbore835 ac of the tubular sleeve. A ring 835 d that defines a passage 835 dafor receiving the tubular support member 815 and a spring 835 e are alsoreceived within the counterbore 835 ac of the tubular sleeve 835 abetween the flange 815 f and the end of the counterbore. The other endof the load transfer pin 835 b is coupled to an end of a tubular sleeve835 f that includes a counterbore 835 fa for receiving the tubularsleeve 835 a, a radial passage 835 fb for receiving a conventionalresilient dog 835 g, a counterbore 835 fc for receiving and mating withthe flange 815 e of the tubular support member 815, a flange 835 fd, anda flange 835 fe including counterbores, 835 ff and 835 fg, that matewith and receive the flange 815 c of the tubular support member, and aradial passage 835 fh.

A first conventional packer cup assembly 840 that defines a passage 440a for receiving the tubular sleeve 835 f includes a first end 840 b thatmates with the flange 835 fd of the tubular sleeve 835 f, a conventionalsealing cup 840 c, and a second end 840 d. A tubular spacer 845 thatdefines a passage 845 a for receiving the tubular sleeve 835 f includesa first end 845 b that mates with the second end 840 d of the firstpacker cup assembly 840 and a second end 845 c. A second conventionalpacker cup assembly 850 that defines a passage 850 a for receiving thetubular sleeve 835 f includes a first end 850 b that mates with thesecond end 845 c of the spacer 845, a conventional sealing cup 850 c,and a second end 850 d that mates with the flange 835 fe of the tubularsleeve.

In an exemplary embodiment, during operation of the apparatus 800, asillustrated in FIGS. 15 and 15 a-15 j, the apparatus may be initiallypositioned in the wellbore 100, within the casing 110, with the dogassembly 835 positioned in a neutral position in which the radialpassage 815 d of the tubular support member 815 is fluidicly coupled tothe radial passage 835 fh of the dog assembly 835 and the expansion conesegments 825 are not driven up the tapered hexagonal portion 815 gb ofthe expansion cone support body 815 g of the tubular support member 815into contact with the stop member 320. In this manner, fluidic materialswithin the interior 815 a of the tubular support member 815 may passthrough the radial passages, 815 d and 835 fh, into the annulus betweenthe apparatus 800 and the casing 110 thereby preventing overpressurization of the annulus. Furthermore, in this manner, the outsidediameter of the expansion cone segments 825 is less than or equal to theoutside diameter of the stop member 820 thereby permitting the apparatus800 to be displaced within the casing 110.

As illustrated in FIGS. 16, and 16 a-16 c, the apparatus 800 may then bepositioned in the tubular member 120. During the insertion of theapparatus into the tubular member 120, the upper end 120 b of thetubular member may impact the end of the resilient dog 835 g of the dogassembly 835 thereby driving the resilient dog 835 g backwards onto theshoulder 815 ea of the flange 815 e of the tubular support member 815.As a result of the backward axial displacement of the resilient dog 835g, the tubular sleeve 835 f, the pin 835 b, the retaining ring 835 c,the ring 835 d, and the spring 835 e of the dog assembly 835 are drivenbackward thereby compressing the spring 835 e and applying an axialbiasing force to the tubular sleeve 835 a that prevents the expansioncone segments 825 from being displaced toward the end stop 820.

The apparatus 800 may then be at least partially positioned in the openhole section 115 a of the wellbore section 115, beyond the lower end 120c of the tubular member 120. In an exemplary embodiment, that portion ofthe apparatus 800 that includes the stop member 820, the expansion conesegments 825, the split ring collar 830, and the dog assembly 835 isthen positioned in the open hole section 115 a of the wellbore section115, beyond the lower end 120 of the tubular member for reasons to bedescribed. Because the dog 835 g of the dog assembly 835 is resilient,once the apparatus 800 has been positioned in the open hole section 115a of the wellbore section 115, beyond the lower end 120 c of the tubularmember 120, the resilient dog of the dog assembly may spring outwardlyin the radial direction.

The apparatus 800 may then be repositioned at least partially backwithin the tubular member 120. During the re-insertion of the apparatusinto the tubular member 120, the lower end 120 c of the tubular membermay impact the ends of the resilient dog 835 g of the dog assembly 835thereby driving the resilient dog forward until the resilient dog ispositioned onto the shoulder 815 eb of the flange 815 e of the tubularsupport member 815.

As a result of the forward axial displacement of the resilient dog 835g, the tubular sleeve 835 f, the spring 835 e, the ring 835 d, the ring835 c, the pin 835 b, and the tubular sleeve 835 a are displaced in theforward axial direction thereby also displacing the split ring collar830 and the expansion cone segments 825 in the forward axial direction.As a result, the expansion cone segments 825 are driven up the taperedhexagonal portion 815 gb of the expansion cone support body 815 g of thetubular support member 815 into contact with the stop member 320.Furthermore, as a result of the forward axial displacement of thetubular sleeve 835 f, the radial passages, 815 d and 835 fh, arefluidicly decoupled. As a result fluidic materials within the tubularsupport member 815 may not pass into the annulus between the tubularsupport member and the tubular member 120.

As a result of the forward axial displacement of the resilient dog 435e, the outside diameter of the expansion cone segments 825 is nowgreater than the inside diameter of expandable tubular member 120thereby permitting the apparatus 800 to be used to radially expand andplastically deform the tubular member, and fluidic materials within theinterior 815 a of the tubular support member 815 may no longer passthrough the radial passages, 815 d and 455 ed, into the annulus betweenthe apparatus 800 and the tubular member thereby permitting the interiorof the apparatus to be pressurized.

The apparatus 800 may then be operated to radially expand andplastically deform the tubular member 120 by applying an upward axialforce to the tubular support member 815 and/or by injecting apressurized fluidic material into the tubular support member.

In particular, as illustrated in figs. 17 and 17 a-17 c, the expandabletubular member 120 may then be radially expanded using the apparatus 800by injecting a fluidic material 275 into the apparatus through thepassages 805 a, 810 a, 815 a, and 820 a. The injection of the fluidicmaterial 275 may pressurize the interior 120 a of the expandable tubularmember 120. In addition, because the packer cup assemblies, 840 and 850,seal off an annular region 120 aa below the packer cup assembliesbetween the expandable tubular member 120 and the tubular support member815, the injection of the fluidic material 275 may also pressurize theannular region.

The continued injection of the fluidic material 275 may then pressurizethe interior 120 a of the expandable tubular member 120 therebyplastically deforming and radially expanding the expandable tubularmember off of the expansion cone segments 825. Because the outersurfaces, 825 bb and 825 bc, of the expansion cone segments 825 aretapered, the plastic deformation and radial expansion of the expandabletubular member 120 proximate the expansion cone segments is facilitated.Furthermore, in an exemplary embodiment, the continued injection of thefluidic material 275 also pressurizes the annular region 120 aa definedbetween the interior surface of the expandable tubular member 120 andthe exterior surface of the tubular support member 815 that is boundedon the upper end by the packer cup assembly 840 and on the lower end bythe expansion cone segments 825. Furthermore, in an exemplaryembodiment, the pressurization of the annular region 120 aa alsoradially expands at least a portion of the surrounding portion of theexpandable tubular member 120. In this manner, the plastic deformationand radial expansion of the expandable tubular member 120 is enhanced.Furthermore, during operation of the apparatus 300, the packer cupassemblies 840 and 850 prevent the pressurized fluidic material 275 frompassing above and beyond the packer cup assemblies and thereby definethe length of the pressurized annular region 120 aa. In an exemplaryembodiment, the pressurization of the annular region 120 aa decreasesthe operating pressures required for plastic deformation and radialexpansion of the expandable tubular member 120 by as much as 50% andalso reduces the angle of attack of the tapered external surfaces, 825bb and 825 bc, of the expansion cone segments 825.

The radial expansion of the expandable tubular member 120 may thencontinue until the upper end 120 b of the expandable tubular member isradially expanded and plastically deformed along with the overlappingportion of the wellbore casing 110. Because the expansion cone segments825 may be adjustably positioned from an outside diameter less than theinside diameter of the expandable tubular member 120 to an outsidediameter substantially equal to the inside diameter of the pre-existingcasing 110, the resulting wellbore casing, including the casing 110 andthe radially expanded tubular member 120, created by the operation ofthe apparatus 800 may have a single substantially constant insidediameter thereby providing a mono-diameter wellbore casing.

During the radial expansion process, the expansion cone segments 825 maybe raised out of the expanded portion of the tubular member 120 byapplying an upward axial force to the tubular support member 815. In apreferred embodiment, during the radial expansion process, the expansioncone segments 825 are raised at approximately the same rate as thetubular member 120 is expanded in order to keep the tubular memberstationary relative to the new wellbore section 115.

In a preferred embodiment, when the upper end portion of the expandabletubular member 120 and the lower portion of the wellbore casing 110 thatoverlap with one another are plastically deformed and radially expandedby the expansion cone segments 825, the expansion cone segments aredisplaced out of the wellbore 100 by both the operating pressure withinthe interior of the tubular member 120 and a upwardly directed axialforce applied to the tubular support member 405.

In a preferred embodiment, the operating pressure and flow rate of thefluidic material 275 is controllably ramped down when the expansion conesegments 825 reach the upper end portion of the expandable tubularmember 120. In this manner, the sudden release of pressure caused by thecomplete radial expansion and plastic deformation of the expandabletubular member 120 off of the expansion cone segments 825 can beminimized. In a preferred embodiment, the operating pressure is reducedin a substantially linear fashion from 100% to about 10% during the endof the extrusion process beginning when the expansion cone segments 825are within about 5 feet from completion of the extrusion process.

Alternatively, or in combination, the wall thickness of the upper endportion of the expandable tubular member 120 is tapered in order togradually reduce the required operating pressure for plasticallydeforming and radially expanding the upper end portion of the tubularmember. In this manner, shock loading of the apparatus is at leastreduced.

Alternatively, or in combination, a shock absorber is provided in thetubular support member 805 in order to absorb the shock caused by thesudden release of pressure. The shock absorber may comprise, forexample, any conventional commercially available shock absorber, bumpersub, or jars adapted for use in wellbore operations.

Alternatively, or in combination, an expansion cone catching structureis provided in the upper end portion of the expandable tubular member120 in order to catch or at least decelerate the expansion cone segments825.

Alternatively, or in combination, during the radial expansion process,an upward axial force is applied to the tubular support member 815sufficient to plastically deform and radially expand the tubular member120 off of the external surfaces, 225 bb and 225 bc, of the expansioncone segments 825.

Alternatively, or in combination, in order to facilitate thepressurization of the interior 120 a of the expandable tubular member bythe injection of the fluidic materials 275, the region within thewellbore section 115 below the apparatus 800 may be fluidicly sealed offin a convention manner using, for example, a packer.

Once the radial expansion process is completed, the tubular supportmember 805, the tubular support member 810, the tubular support member815, the end stop 820, the expansion cone segments 825, the split ringcollar 830, the dog assembly 835, the packer cup assembly 840, thespacer 845, and the packer cup assembly 850 are removed from thewellbores 100 and 115.

If the expansion cone segments 825 become lodged within the expandabletubular member 120 during the radial expansion process, then a ball 280may be placed in the throat 815 aa of the passage 815 a of the tubularsupport member 815. The continued injection of the fluidic material 275following the placement of the ball 280 in the throat 815 aa of thepassage 815 a of the tubular support member will then pressurize theradial passage 815 b and an annular portion 835 fga of the counterbore835 fg. As a result of the pressurization of the annular portion 835 fgaof the counterbore 835 fg, the tubular sleeve 835 f, the pin 835 b, theretaining ring 835 c, the ring 835 d, the spring 835 e, and the tubularsleeve 835 a of the dog assembly 835, and the split ring collar 830 aredriven backward thereby displacing the expansion cone segments 825backwards in the axial direction away from the end stop 820. In thismanner, the outside diameter of the expansion cone segments 825 isthereby reduced and the apparatus 800 may then be removed from theexpandable tubular member 120.

Referring now to FIGS. 18 a, 18 b, 18 c, and 18 d, an embodiment of anadjustable expansion cone assembly 900 will be described. The assembly900 includes a tubular support member 905 that defines a passage 905 aand includes an expansion cone support flange assembly 905 b that iscoupled to an end stop 910 that defines a passage 910 a. The expansioncone support flange assembly 905 b includes a first tubular end 905 ba,a second tubular end 905 bb, and an intermediate hexagonal conicaltubular body 905 bc that includes a plurality of substantially identicaland equally spaced apart expansion cone segment support slots 905bcaa-905 bcaf on each of the facets of the hexagonal tubular body.

A plurality of first expansion cone segments 915 a-915 c are providedthat include T-shaped retaining members 915 aa-915 ca that mate with andare movably received within the T-shaped slots 905 bcaa, 905 bcac, and905 bcae of the hexagonal conical tubular body 905 bc of the expansioncone support assembly 905 b, T-shaped retaining members 915 ab-915 cb,exterior top surfaces 915 ac-915 cc, exterior top surfaces 915 ad-915cd, exterior top surfaces 915 ae-915 ce, exterior top surfaces 915af-915 cf, and exterior top surfaces 915 ag-915 cg. In an exemplaryembodiment, the exterior top surfaces 915 ac-915 cc and the exterior topsurfaces 915 ad-915 cd are arcuate conical surfaces in which the angleof attack of the exterior top surfaces 915 ac-915 cc is greater than theangle of attack of the exterior top surfaces 915 ad-915 cd.

A plurality of second expansion cone segments 920 a-920 c, that areinterleaved with and complementary shaped to the first expansion conesegments 915 a-915 c, are also provided that include T-shaped retainingmembers 920 aa-920 ca that mate with and are movably received within theT-shaped slots 905 bcab, 905 bcad, and 905 bcaf of the hexagonal conicaltubular body 905 bc of the expansion cone support assembly 905 b,T-shaped retaining members 920 ab-920 cb, exterior top surfaces 920ac-920 cc, exterior top surfaces 920 ad-920 cd, exterior top surfaces920 ae-920 ce, exterior top surfaces 920 af-920 cf, and exterior topsurfaces 920 ag-920 cg. In an exemplary embodiment, the exterior topsurfaces 920 ac-920 cc and the exterior top surfaces 920 ad-920 cd arearcuate conical surfaces in which the angle of attack of the exteriortop surfaces 920 ac-920 cc is greater than the angle of attack of theexterior top surfaces 920 ad-920 cd.

A split ring collar 925 is provided that defines a passage 925 a forreceiving the tubular support member 905 that includes an L-shapedretaining member 925 b at one end and another end of the split ringcollar 925 includes T-shaped slots, 925 c, 925 d, 925 e, 925 f, 925 g,and 925 h, for mating with and receiving the T-shaped retaining members,915 ab, 920 ab, 915 bb, 920 bb, 915 cb, and 920 cb, of the expansioncone segments, 915 a, 920 a, 915 b, 920 b, 915 c, and 920 c,respectively. A tubular sleeve 930 is provided that defines a passage930 a for receiving the tubular support member 905 and that alsoincludes a slot 930 b for receiving and mating with the L-shapedretaining member 925 b of the split ring collar 925.

During operation of the assembly 900, as illustrated in FIGS. 18 a, 18b, 18 c, and 18 d, in an unexpanded position, the expansion conesegments, 915 a, 915 b, 915 c, 915 d, 920 a, 920 b, 920 c, and 920 d arepositioned adjacent to the base of the hexagonal conical tubular body905 bc of the expansion cone support flange 905 b away from the end stop910. In this manner, the outside diameter of the expansion cone segmentsis less than or equal to the maximum outside diameter of the assembly.Furthermore, in the unexpanded position, the expansion cone segments,915 a, 915 b, and 915 c, are positioned further away from the end stop910 than the expansion cone segments, 920 a, 920 b, and 920 c.

As illustrated in FIGS. 19 and 19 a, the assembly 900 may then beexpanded by displacing the tubular sleeve 930 and the split ring collar925 in the axial direction towards the expansion cone segment supportmembers 705 bb. As a result, the expansion cone segments, 915 a, 915 b,915 c, 920 a, 920 b, 920 c, are driven up the hexagonal conical tubularbody 905 bc of the expansion cone support flange 905 b until theexpansion cone segments impact the end stop 910. In this manner, theoutside diameter of the expansion segments, 915 a, 915 b, 915 c, 920 a,920 b, and 920 c, is greater than the maximum diameter of the remainingcomponents of the assembly 900. Furthermore, the conical outer surfaces,915 ac, 915 bc, 915 cc, 920 ac, 920 bc, and 920 cc, and the conicalouter surfaces, 915 ad, 915 bd, 915 cd, 920 ad, 920 bd, and 920 cd ofthe expansion cone segments, 915 a, 915 b, 915 c, 920 a, 920 b, and 920c, respectively, may now be used to radially expand a tubular member. Inan exemplary embodiment, the outer conical surfaces, 915 ac, 915 bc, 915cc, 920 ac, 920 bc, and 920 cc, and the conical outer surfaces, 915 ad,915 bd, 915 cd, 920 ad, 920 bd, and 920 cd of the expansion conesegments, 915 a, 915 b, 915 c, 920 a, 920 b, and 920 c, respectively, inthe expanded position of the assembly 900, provide a substantiallycontinuous outer conical surfaces in the circumferential direction.Furthermore, note that in the expanded position of the assembly 900, thefirst set of expansion cone segments, 915 a, 915 b, and 915 c, arebrought into alignment with the second set of expansion cone segments,920 a, 920 b, and 920 c.

The assembly 900 may then be returned to the unexpanded position bydisplacing the tubular sleeve 930 and the split ring collar 925 in theaxial direction away from the end stop 910. As a result, the expansioncone segments, 915 a, 915 b, 915 c, 920 a, 920 b, and 920 c, aredisplaced away from the end top 910, down the conical hexagonal tubularmember 905 bc and thereby are returned to a position in which theoutside diameter of the expansion cone segments is less than or equal tothe maximum diameter of the remaining components of the assembly 900.

In several alternative embodiments, the assembly 900 is incorporatedinto the assemblies 200, 300, 400, and 800.

Referring to FIG. 20 a, an embodiment of an expansion cone segmentassembly 1000 includes interlocking expansion cone segments, 1000 a,1000 b, 1000 c, 1000 d, 1000 e, and 1000 f.

Referring to FIG. 20 b, an embodiment of an expansion cone segmentassembly 1100 includes interlocking expansion cone segments, 1100 a,1100 b, 1100 c, 1100 d, 1100 e, and 1100 f.

Referring to FIG. 20 c, an embodiment of an expansion cone segmentassembly 1200 includes interlocking expansion cone segments, 1200 a,1200 b, 1200 c, 1200 d, 1200 e, and 1200 f.

Referring to FIG. 20 d, an embodiment of an expansion cone segmentassembly 1300 includes interlocking expansion cone segments, 1300 a,1300 b, 1300 c, 1300 d, 1300 e, and 1300 f.

Referring to FIG. 20 e, an embodiment of an expansion cone segmentassembly 1400 includes interlocking expansion cone segments, 1400 a,1400 b, 1400 c, 1400 d, 1400 e, and 1400 f.

Referring to FIG. 20 f, an embodiment of an expansion cone segmentassembly 1500 includes interlocking expansion cone segments, 1500 a,1500 b, 1500 c, 1500 d, 1500 e, and 1500 f.

Referring to FIG. 20 g, an embodiment of an expansion cone segmentassembly 1600 includes interlocking expansion cone segments, 1600 a,1600 b, 1600 c, 1600 d, 1600 e, and 1600 f.

Referring to FIG. 20 h, an embodiment of an expansion cone segmentassembly 1700 includes interlocking expansion cone segments, 1700 a,1700 b, 1700 c, 1700 d, 1700 e, and 1700 f.

Referring to FIG. 20 i, an embodiment of an expansion cone segmentassembly 1800 includes interlocking expansion cone segments, 1800 a,1800 b, 1800 c, 1800 d, 1800 e, and 1800 f.

Referring to FIG. 20 j, an embodiment of an expansion cone segmentassembly 1900 includes interlocking expansion cone segments, 1900 a,1900 b, 1900 c, 1900 d, 1900 e, and 1900 f.

Referring to FIG. 20 k, an embodiment of an expansion cone segmentassembly 2000 includes interlocking expansion cone segments, 2000 a,2000 b, 2000 c, 2000 d, 2000 e, and 2000 f.

Referring to FIG. 20 l, an embodiment of an expansion cone segmentassembly 2100 includes interlocking expansion cone segments, 2100 a,2100 b, 2100 c, 2100 d, 2100 e, and 2100 f.

Referring to FIG. 20 m, an embodiment of an expansion cone segmentassembly 2200 includes interlocking expansion cone segments, 2200 a,2200 b, 2200 c, 2200 d, 2200 e, and 2200 f.

The expansion cone segment assemblies 1000, 1100, 1200, 1300, 1400,1500, 1600, 1700, 1800, 1900, 2000, 2100, and 2200 provide enhancedoperational properties such as, for example, efficient radial expansionof expandable tubular members and durability during operation.

In several alternative embodiments, the design and operational featuresof the apparatus 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100,1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, and 2200 maybe combined, in whole or in part, and/or the design and operationalelements of the apparatus 200, 300, 400, 500, 600, 700, 800, 900, 1000,1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, and2200 may be interspersed among each other.

In several alternative embodiments, the apparatus 200, 300, 400, 500,600, 700, 800, 900, and 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700,1800, 1900, 2000, 2100, and 2200 may be used to form or repair wellborecasings, pipelines, or structural supports.

In several alternative embodiments, the apparatus 200, 300, 400, 500,600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700,1800, 1900, 2000, 2100, and 2200 include two or more expansion conesegments that may be movably support and guided on a tapered expansioncone support body that may, for example, be conical, or may be amulti-sided body.

In several alternative embodiments, the design and operation of theapparatus 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200,1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, and 2200 areprovided substantially as disclosed in one or more of the following: (1)U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2)U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3)U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4)U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5)U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6)U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7)U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8)U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9)U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000,(10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9,2000, (11) U.S. provisional patent application Ser. No. 60/162,671,filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No.60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patentapplication Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S.provisional patent application Ser. No. 60/159,039, filed on Oct. 12,1999, (15) U.S. provisional patent application Ser. No. 60/159,033,filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser.No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patentapplication Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S.provisional patent application Ser. No. 60/221,443, filed on Jul. 28,2000, (19) U.S. provisional patent application Ser. No. 60/221,645,filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser.No. 60/233,638, filed on Sep. 18, 2000, (21) U.S. provisional patentapplication Ser. No. 60/237,334, filed on Oct. 2, 2000, (22) U.S.provisional patent application Ser. No. 60/270,007, filed on Feb. 20,2001; and (23) U.S. provisional patent application Ser. No. 60/262,434,filed on Jan. 17, 2001; and (24) U.S. provisional patent applicationSer. No. 60/259,486, filed on Jan. 3, 2001, the disclosures of which areincorporated herein by reference.

An apparatus for radially expanding a tubular member has been describedthat includes a tubular support member that includes a first tubularsupport body defining a longitudinal passage, a first lug coupled to andextending from the first tubular support body in the radial direction, asecond lug coupled to and extending from the first tubular support bodyin the radial direction, and an expansion cone support body coupled tothe first tubular support body. The expansion cone support body includesan N-sided tapered tubular support member, wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot. Nexpansion cone segments are movably coupled to the expansion conesupport body, each including an expansion cone segment body includingarcuate conical outer surfaces, a first T-shaped retaining membercoupled to the expansion cone segment body for movably coupling theexpansion cone segment body to a corresponding one of the T-shaped slotsof the expansion cone support body, and a second T-shaped retainingmember coupled to the expansion cone segment body. A split ring collarassembly is movably coupled to the exterior of the tubular supportmember that includes a second tubular support body defining N T-shapedslots for movably receiving corresponding ones of the second T-shapedretaining members of the expansion cone segments, and an L-shapedretaining member coupled to the second tubular support body. A firstdrag block assembly is movably coupled to the tubular support memberthat includes a first drag block body defining a slot for receiving andmating with the L-shaped retaining member of the split ring collar, anda first J-shaped slot for receiving the first lug, and one or more firstdrag blocks coupled to the first drag block body. A second drag blockassembly is movably coupled to the tubular support member that includesa second drag block body defining a second J-shaped slot for receivingthe second lug, and one or more second drag blocks coupled to the seconddrag block body. First and second packer cups are coupled to the tubularsupport member between the first and second drag block assemblies.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage, a first flangecoupled to the first tubular support body, a second flange coupled tothe first tubular support body, a first tapered flange coupled to thefirst tubular support body, a second tapered flange coupled to the firsttubular support body, and an expansion cone support body coupled to thefirst tubular support body. The expansion cone support body includes anN-sided tapered tubular support member, wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot. Nexpansion cone segments are movably coupled to the expansion conesupport body, each including an expansion cone segment body includingarcuate conical outer surfaces, a first T-shaped retaining membercoupled to the expansion cone segment body for movably coupling theexpansion cone segment body to a corresponding one of the T-shaped slotsof the expansion cone support body, and a second T-shaped retainingmember coupled to the expansion cone segment body. A split ring collaris movably coupled to the exterior of the tubular support member thatincludes a second tubular support body that defines N T-shaped slots formovably receiving corresponding ones of the second T-shaped retainingmembers of the expansion cone segments, and an L-shaped retaining membercoupled to the second tubular support body. A first collet assembly ismovably coupled to the tubular support member that includes a firsttubular sleeve that defines a slot for receiving and mating with theL-shaped retaining member of the split ring collar, a first counterborefor receiving the first flange, and a first radial passage, a firstspring received within the first counterbore, a first retaining ringreceived within the first counterbore, a first load transfer pin coupledto the first retaining ring and extending through the first radialpassage, a second tubular sleeve coupled to the first load transfer pin,a first resilient collet coupled to the second tubular sleeve andpositioned above the first tapered flange, and a third tubular sleevecoupled to the first resilient collet. A second collet assembly ismovably coupled to the tubular support member that includes a fourthtubular sleeve that defines a second counterbore for receiving thesecond flange, and a second radial passage, a second spring receivedwithin the second counterbore, a second retaining ring received withinthe second counterbore, a second load transfer pin coupled to the secondretaining ring and extending through the second radial passage, a fifthtubular sleeve coupled to the second load transfer pin, a secondresilient collet coupled to the fifth tubular sleeve and positionedabove the second tapered flange, and a sixth tubular sleeve coupled tothe second resilient collet. First and second packer cups coupled to thetubular support member between the first and second collet assemblies.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage, a first radialpassage defined in the first tubular support body fluidicly coupled tothe longitudinal passage, a first flange coupled to the first tubularsupport body, a second flange coupled to the first tubular support body,a first tapered flange coupled to the first tubular support body, asecond tapered flange coupled to the first tubular support body, and anexpansion cone support body coupled to the first tubular support body.The expansion cone support body includes an N-sided tapered tubularsupport member, wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot. N expansion cone segments aremovably coupled to the expansion cone support body, each including anexpansion cone segment body including arcuate conical outer surfaces, afirst T-shaped retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody, and a second T-shaped retaining member coupled to the expansioncone segment body. A split ring collar is movably coupled to theexterior of the tubular support member that includes a second tubularsupport body that defines N T-shaped slots for movably receivingcorresponding ones of the second T-shaped retaining members of theexpansion cone segments, and an L-shaped retaining member coupled to thesecond tubular support body. A first dog assembly is movably coupled tothe tubular support member that includes a first tubular sleeve thatdefines a slot for receiving and mating with the L-shaped retainingmember of the split ring collar, a first counterbore for receiving thefirst flange, and a second radial passage, a first spring receivedwithin the first counterbore, a first retaining ring received within thefirst counterbore, a first load transfer pin coupled to the firstretaining ring and extending through the second radial passage, and asecond tubular sleeve coupled to the first load transfer pin thatdefines a second counterbore for receiving the first tubular sleeve, afirst resilient dog coupled to the second tubular sleeve and positionedadjacent to the first tapered flange. A second dog assembly is movablycoupled to the tubular support member that includes a third tubularsleeve that defines a second counterbore for receiving the secondflange, a third radial passage, and a fourth radial passage fluidiclycoupled to the first radial passage, a second spring received within thesecond counterbore, a second retaining ring received within the secondcounterbore, a second load transfer pin coupled to the second retainingring and extending through the third radial passage, a fourth tubularsleeve coupled to the second load transfer pin, and a second resilientdog coupled to the fourth tubular sleeve and positioned adjacent to thesecond tapered flange. First and second packer cups are coupled to thetubular support member between the first and second dog assemblies.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage including a throatpassage, a first radial passage defined in the first tubular supportbody fluidicly coupled to the longitudinal passage, a first flangecoupled to the first tubular support body, a second flange coupled tothe first tubular support body that defines a second radial passagedefined in the second flange fluidicly coupled to the longitudinalpassage, a tapered flange coupled to the first tubular support body, andan expansion cone support body coupled to the first tubular supportbody. The expansion cone support body includes an N-sided taperedtubular support member, wherein each side of the multi-sided taperedtubular support member defines a T-shaped slot. N expansion conesegments are movably coupled to the expansion cone support body, eachincluding an expansion cone segment body including arcuate conical outersurfaces, a first T-shaped retaining member coupled to the expansioncone segment body for movably coupling the expansion cone segment bodyto a corresponding one of the T-shaped slots of the expansion conesupport body, and a second T-shaped retaining member coupled to theexpansion cone segment body. A split ring collar is movably coupled tothe exterior of the tubular support member that includes a secondtubular support body that defines N T-shaped slots for movably receivingcorresponding ones of the second T-shaped retaining members of theexpansion cone segments, and an L-shaped retaining member coupled to thesecond tubular support body. A dog assembly is movably coupled to thetubular support member that includes a first tubular sleeve that definesa slot for receiving and mating with the L-shaped retaining member ofthe split ring collar, a first counterbore for receiving the firstflange, and a third radial passage, a spring received within the firstcounterbore, a retaining ring received within the first counterbore, aload transfer pin coupled to the retaining ring and extending throughthe third radial passage, a second tubular sleeve coupled to the firstload transfer pin that defines a first counterbore for receiving thefirst tubular sleeve, a second counterbore for receiving and mating withthe tapered flange, and includes a third flange that defines a thirdcounterbore for receiving the second flange, a fourth counterbore forreceiving the second flange, and a fourth radial passage, and aresilient dog coupled to the second tubular sleeve and positionedadjacent to the tapered flange. First and second packer cups are coupledto the tubular support member between the resilient dog and the thirdflange.

An adjustable expansion cone assembly has also been described thatincludes a tubular support member that includes a tubular support bodyand an expansion cone support body coupled to the tubular support body.The expansion cone support body includes an N-sided tapered tubularsupport member, wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot. N expansion cone segments aremovably coupled to the expansion cone support body, each including anexpansion cone segment body including arcuate conical outer surfaces, afirst T-shaped retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody, and a second T-shaped retaining member coupled to the expansioncone segment body. A split ring collar is movably coupled to theexterior of the tubular support member that includes a second tubularsupport body that defines N T-shaped slots for movably receivingcorresponding ones of the second T-shaped retaining members of theexpansion cone segments, and an L-shaped retaining member coupled to thesecond tubular support body. A tubular actuating sleeve is movablycoupled to the tubular support member that includes a third tubularsupport body that defines a slot for receiving and mating with theL-shaped retaining member of the split ring collar.

An adjustable expansion cone assembly has also been described thatincludes a tubular support member that includes a first tubular supportbody, and an expansion cone support body coupled to the tubular supportbody. The expansion cone support body includes a tapered tubular supportmember defining N stepped slots. An expansion cone assembly is movablycoupled to the tubular support member that includes a second tubularsupport body movably coupled to the first tubular support body definingan L-shaped slot, and N expansion cone segments extending from thesecond tubular support member. Each expansion cone segment includes aresilient collet coupled to the second tubular support member, anexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces, and a retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the stepped slots of theexpansion cone support body. A split ring collar is movably coupled tothe exterior of the tubular support member that includes a third tubularsupport body, a first L-shaped retaining member coupled to the thirdtubular support body for mating with the L-shaped slot of the secondtubular support body of the expansion cone assembly, and a secondL-shaped retaining member coupled to the third tubular body. A tubularactuating sleeve is movably coupled to the tubular support member thatincludes a third tubular support body that defines a slot for receivingand mating with the second L-shaped retaining member of the split ringcollar.

An adjustable expansion cone assembly has also been described thatincludes a tubular support member that includes a first tubular supportbody, and an expansion cone support body coupled to the tubular supportbody. The expansion cone support body includes a tapered tubular supportmember defining N slots. An expansion cone assembly is movably coupledto the tubular support member that includes a second tubular supportbody movably coupled to the first tubular support body defining anL-shaped slot, and N expansion cone segments extending from the secondtubular support member. Each expansion cone segment includes a resilientcollet coupled to the second tubular support member, an expansion conesegment body coupled to the resilient collet including arcuate conicalouter surfaces, and a retaining member coupled to the expansion conesegment body for movably coupling the expansion cone segment body to acorresponding one of the slots of the expansion cone support body. Asplit ring collar is movably coupled to the exterior of the tubularsupport member that includes a third tubular support body, a firstL-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body, and asecond L-shaped retaining member coupled to the third tubular supportbody. A tubular actuating sleeve is movably coupled to the tubularsupport member that includes a third tubular support body that defines aslot for receiving and mating with the second L-shaped retaining memberof the split ring collar.

An adjustable expansion cone assembly has also been described thatincludes a tubular support member that includes a first tubular supportbody, and an expansion cone support body coupled to the tubular supportbody. The expansion cone support body includes a tapered tubular supportmember defining N slots. An expansion cone assembly is movably coupledto the tubular support member that includes a second tubular supportbody movably coupled to the first tubular support body defining anL-shaped slot, N/2 first expansion cone segments extending from thesecond tubular support member, and N/2 second expansion cone segmentsextending from the second tubular member. Each first expansion conesegment includes a first resilient collet coupled to the second tubularsupport member, a first expansion cone segment body coupled to theresilient collet including arcuate conical outer surfaces, and a firstretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theslots of the expansion cone support body. Each second expansion conesegment includes a second resilient collet coupled to the second tubularsupport member, a second expansion cone segment body coupled to theresilient collet including arcuate conical outer surfaces, and a secondretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theslots of the expansion cone support body. The second expansion conesegments overlap and are interleaved with the first expansion conesegments. A split ring collar is movably coupled to the exterior of thetubular support member that includes a third tubular support body, afirst L-shaped retaining member coupled to the third tubular supportbody for mating with L-shaped slot of the second tubular support body,and a second L-shaped retaining member coupled to the third tubularsupport body. A tubular actuating sleeve is movably coupled to thetubular support member that includes a third tubular support body thatdefines a slot for receiving and mating with the second L-shapedretaining member of the split ring collar.

An adjustable expansion cone assembly has also been described thatincludes a tubular support member that includes a first tubular supportbody, and an expansion cone support body coupled to the first tubularsupport body. The expansion cone support body includes an N-sidedtapered tubular support member, wherein each side of the multi-sidedtapered tubular support member defines a T-shaped slot. N/2 firstexpansion cone segments are movably coupled to the expansion conesupport body, each including a first expansion cone segment bodyincluding arcuate conical outer surfaces, a first T-shaped retainingmember coupled to the first expansion cone segment body for movablycoupling the first expansion cone segment body to a corresponding one ofthe T-shaped slots of the expansion cone support body, and a secondT-shaped retaining member coupled to the first expansion cone segmentbody. N/2 second expansion cone segments are also movably coupled to theexpansion cone support body, each including a second expansion conesegment body including arcuate conical outer surfaces, a third T-shapedretaining member coupled to the second expansion cone segment body formovably coupling the second expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody, and a fourth T-shaped retaining member coupled to the expansioncone segment body. The first and second expansion cone segments areinterleaved. The first expansion cone segment bodies are complementaryshaped with respect to the second expansion cone segment bodies. A splitring collar assembly is movably coupled to the exterior of the tubularsupport member that includes a second tubular support body that definesN T-shaped slots for movably receiving corresponding ones of the secondand fourth T-shaped retaining members of the interleaved first andsecond expansion cone segments, and an L-shaped retaining member coupledto the second tubular support body. A tubular actuating sleeve movablycoupled to the tubular support member that includes a third tubularsupport body that defines a slot for receiving and mating with theL-shaped retaining member of the split ring collar.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage, a first lugcoupled to and extending from the first tubular support body in theradial direction, and a second lug coupled to and extending from thefirst tubular support body in the radial direction. An adjustableexpansion cone assembly is movably coupled to the tubular supportmember. A first drag block assembly is movably coupled to the tubularsupport member that includes a first drag block body coupled to theadjustable expansion cone assembly that defines: a first J-shaped slotfor receiving the first lug, and one or more first drag blocks coupledto the first drag block body. A second drag block assembly is movablycoupled to the tubular support member that includes a second drag blockbody that defines: a second J-shaped slot for receiving the second lug,and one or more second drag blocks coupled to the second drag blockbody. First and second packer cups are coupled to the tubular supportmember between the first and second drag block assemblies.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage, a first flangecoupled to the first tubular support body, a second flange coupled tothe first tubular support body, a first tapered flange coupled to thefirst tubular support body, and a second tapered flange coupled to thefirst tubular support body. An adjustable expansion cone assembly ismovably coupled to the tubular support member. A first collet assemblyis movably coupled to the tubular support member that includes a firsttubular sleeve coupled to the adjustable expansion cone assembly anddefines a first counterbore for receiving the first flange, and a firstradial passage, a first spring received within the first counterbore, afirst retaining ring received within the first counterbore, a first loadtransfer pin coupled to the first retaining ring and extending throughthe first radial passage, a second tubular sleeve coupled to the firstload transfer pin, a first resilient collet coupled to the secondtubular sleeve and positioned above the first tapered flange, and athird tubular sleeve coupled to the first resilient collet. A secondcollet assembly is movably coupled to the tubular support member thatincludes a fourth tubular sleeve that defines: a second counterbore forreceiving the second flange, and a second radial passage, a secondspring received within the second counterbore, a second retaining ringreceived within the second counterbore, a second load transfer pincoupled to the second retaining ring and extending through the secondradial passage, a fifth tubular sleeve coupled to the second loadtransfer pin, a second resilient collet coupled to the fifth tubularsleeve and positioned above the second tapered flange, and a sixthtubular sleeve coupled to the second resilient collet. First and secondpacker cups are coupled to the tubular support member between the firstand second collet assemblies.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage, a first radialpassage defined in the first tubular support body fluidicly coupled tothe longitudinal passage, a first flange coupled to the first tubularsupport body, a second flange coupled to the first tubular support body,a first tapered flange coupled to the first tubular support body, and asecond tapered flange coupled to the first tubular support body. Anadjustable expansion cone assembly is movably coupled to the tubularsupport member. A first dog assembly is movably coupled to the tubularsupport member that includes a first tubular sleeve coupled to theadjustable expansion cone assembly that defines: a first counterbore forreceiving the first flange, and a second radial passage, a first springreceived within the first counterbore, a first retaining ring receivedwithin the first counterbore, a first load transfer pin coupled to thefirst retaining ring and extending through the second radial passage, asecond tubular sleeve coupled to the first load transfer pin thatdefines: a second counterbore for receiving the first tubular sleeve, afirst resilient dog coupled to the second tubular sleeve and positionedadjacent to the first tapered flange. A second dog assembly is movablycoupled to the tubular support member that includes a third tubularsleeve that defines a second counterbore for receiving the secondflange, a third radial passage, and a fourth radial passage fluidiclycoupled to the first radial passage, a second spring received within thesecond counterbore, a second retaining ring received within the secondcounterbore, a second load transfer pin coupled to the second retainingring and extending through the third radial passage, a fourth tubularsleeve coupled to the second load transfer pin, a second resilient dogcoupled to the fourth tubular sleeve and positioned adjacent to thesecond tapered flange. First and second packer cups are coupled to thetubular support member between the first and second dog assemblies.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member that includes a firsttubular support body defining a longitudinal passage including a throatpassage, a first radial passage defined in the first tubular supportbody fluidicly coupled to the longitudinal passage, a first flangecoupled to the first tubular support body, and a second flange coupledto the first tubular support body that defines: a second radial passagedefined in the second flange fluidicly coupled to the longitudinalpassage. An adjustable expansion cone assembly is movably coupled to thetubular support member. A dog assembly is movably coupled to the tubularsupport member that includes a first tubular sleeve coupled to theadjustable expansion cone assembly that defines a first counterbore forreceiving the first flange, and a third radial passage, a springreceived within the first counterbore, a retaining ring received withinthe first counterbore, a load transfer pin coupled to the retaining ringand extending through the third radial passage, a second tubular sleevecoupled to the first load transfer pin that defines: a first counterborefor receiving the first tubular sleeve, a second counterbore forreceiving and mating with the tapered flange, and includes a thirdflange that defines a third counterbore for receiving the second flange,a fourth counterbore for receiving the second flange, and a fourthradial passage, and a resilient dog coupled to the second tubular sleeveand positioned adjacent to the tapered flange. First and second packercups are coupled to the tubular support member between the resilient dogand the third flange.

An apparatus for radially expanding a tubular member has also beendescribed that includes a tubular support member, an adjustableexpansion cone assembly movably coupled to the tubular support member,and means for adjusting the adjustable expansion cone assembly.

An adjustable expansion cone assembly has also been described thatincludes a tubular support member. An adjustable expansion cone ismovably coupled to the tubular support member that includes a pluralityof expansion cone segments, and means for guiding the expansion conesegments on the tubular support member. The assembly further includesmeans for adjusting the adjustable expansion cone.

A method of operating an adjustable expansion cone assembly including aplurality of expansion cone segments has also been described thatincludes guiding the expansion cone segments on a tapered body, andcontrollably displacing the expansion cone segments along the taperedbody.

A method of operating an adjustable expansion cone assembly including aplurality of expansion cone segments has also been described thatincludes guiding the expansion cone segments on a multi-sided taperedbody, interlocking the expansion cone segments, and controllablydisplacing the expansion cone segments along the tapered body.

A method of operating an adjustable expansion cone assembly including aplurality of expansion cone segments has also been described thatincludes resiliently guiding the expansion cone segments on amulti-sided tapered body, guiding each of the expansion cone segments onopposite sides in the circumferential direction, interlocking theexpansion cone segments, and controllably displacing the expansion conesegments along the tapered body.

A method of operating an adjustable expansion cone assembly including aplurality of expansion cone segments has also been described thatincludes dividing the expansion cone segments into first and secondgroups of expansion cone segments, interleaving the first and secondgroups of expansion cone segments, overlapping the first and secondgroups of expansion cone segments, resiliently guiding the expansioncone segments on a multi-sided tapered body, guiding each of theexpansion cone segments on opposite sides in the circumferentialdirection, and controllably displacing the expansion cone segments alongthe tapered body.

A method of operating an adjustable expansion cone assembly including aplurality of expansion cone segments has also been described thatincludes dividing the expansion cone segments into first and secondgroups of expansion cone segments, interleaving the first and secondgroups of expansion cone segments, guiding the expansion cone segmentson a multi-sided tapered body, and controllably displacing the expansioncone segments along the tapered body while also relatively displacingthe first and second groups of expansion cone segments in oppositedirections.

A method of plastically deforming and radially expanding an expandabletubular member using an apparatus including a tubular support member, anadjustable expansion cone assembly movably coupled to the tubularsupport member, and an actuator movably coupled to the tubular supportmember for adjusting the adjustable expansion cone assembly, has alsobeen described that includes coupling a first end of the expandabletubular member to a tubular structure, locking the actuator to thetubular support member of the apparatus, inserting the apparatus intothe first end of the expandable tubular member, moving the actuator andthe adjustable expansion cone assembly of the apparatus out of thesecond end of the expandable tubular member, reinserting the actuator ofthe apparatus into the second end of the expandable tubular member,unlocking the actuator from the tubular support member of the apparatus,rotating the actuator relative to the tubular support member of theapparatus, and increasing the outside diameter of the adjustableexpansion cone assembly by moving the tubular support member relative tothe actuator, the adjustable expansion cone assembly and the expandabletubular member, and plastically deforming and radially expanding theexpandable tubular member by moving the adjustable expansion coneassembly through the expandable tubular member.

A method of plastically deforming and radially expanding an expandabletubular member using an apparatus including a tubular support member, anadjustable expansion cone assembly movably coupled to the tubularsupport member, and an actuator movably coupled to the tubular supportmember for adjusting the adjustable expansion cone assembly, has alsobeen described that includes coupling a first end of the expandabletubular member to a tubular structure, inserting the apparatus into thefirst end of the expandable tubular member in a first direction,displacing the actuator of the apparatus in a second direction oppositeto the first direction, applying a resilient biasing force to theadjustable expansion cone assembly in the second direction, moving theactuator and the adjustable expansion cone assembly of the apparatus outof the second end of the expandable tubular member, reinserting theactuator of the apparatus into the second end of the expandable tubularmember in the second direction, increasing the outside diameter of theadjustable expansion cone assembly by displacing the actuator and theadjustable expansion cone assembly relative to the expandable tubularmember in the first direction, and plastically deforming and radiallyexpanding the expandable tubular member by moving the adjustableexpansion cone assembly through the expandable tubular member in thesecond direction.

An adjustable expansion cone assembly has also been described thatincludes a plurality of expansion cone segments, means for guiding theexpansion cone segments on a tapered body, and means for controllablydisplacing the expansion cone segments along the tapered body.

An adjustable expansion cone assembly has also been described thatincludes a plurality of expansion cone segments, means for guiding theexpansion cone segments on a multi-sided tapered body, means forinterlocking the expansion cone segments, and means for controllablydisplacing the expansion cone segments along the tapered body.

An adjustable expansion cone assembly has also been described thatincludes a plurality of expansion cone segments, means for resilientlyguiding the expansion cone segments on a multi-sided tapered body, meansfor guiding each of the expansion cone segments on opposite sides in thecircumferential direction, means for interlocking the expansion conesegments, and means for controllably displacing the expansion conesegments along the tapered body.

An adjustable expansion cone assembly has also been described thatincludes a plurality of expansion cone segments, means for dividing theexpansion cone segments into first and second groups of expansion conesegments, means for interleaving the first and second groups ofexpansion cone segments, means for overlapping the first and secondgroups of expansion cone segments, means for resiliently guiding theexpansion cone segments on a multi-sided tapered body, means for guidingeach of the expansion cone segments on opposite sides in thecircumferential direction, and means for controllably displacing theexpansion cone segments along the tapered body.

An adjustable expansion cone assembly has also been described thatincludes a plurality of expansion cone segments, means for dividing theexpansion cone segments into first and second groups of expansion conesegments, means for interleaving the first and second groups ofexpansion cone segments, means for guiding the expansion cone segmentson a multi-sided tapered body, and means for controllably displacing theexpansion cone segments along the tapered body while also relativelydisplacing the first and second groups of expansion cone segments inopposite directions.

An apparatus for plastically deforming and radially expanding anexpandable tubular member has also been described that includes atubular support member, an adjustable expansion cone assembly movablycoupled to the tubular support member, means for actuating theadjustable expansion cone assembly, means for locking the actuator tothe tubular support member of the apparatus, means for unlocking theactuator from the tubular support member of the apparatus, and means forincreasing the outside diameter of the adjustable expansion coneassembly by moving the tubular support member relative to the actuator,the adjustable expansion cone assembly, and the expandable tubularmember.

An apparatus for plastically deforming and radially expanding anexpandable tubular member has also been described that includes atubular support member, an adjustable expansion cone assembly movablycoupled to the tubular support member, means for actuating theadjustable expansion cone assembly, means for displacing the actuator ofthe apparatus in a first direction, means for applying a resilientbiasing force to the adjustable expansion cone assembly when theactuator is displaced in the first direction, and means for increasingthe outside diameter of the adjustable expansion cone assembly bydisplacing the actuator and the adjustable expansion cone assemblyrelative to the expandable tubular member in a second direction oppositeto the first direction.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. An apparatus for radially expanding a tubular member, comprising: atubular support member comprising: a first tubular support body defininga longitudinal passage; a first lug coupled to and extending from thefirst tubular support body in the radial direction; a second lug coupledto and extending from the first tubular support body in the radialdirection; and an expansion cone support body coupled to the firsttubular support body comprising: an N-sided tapered tubular supportmember; wherein each side of the multi-sided tapered tubular supportmember defines a T-shaped slot; N expansion cone segments movablycoupled to the expansion cone support body, each comprising: anexpansion cone segment body including arcuate conical outer surfaces; afirst T-shaped retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody; and a second T-shaped retaining member coupled to the expansioncone segment body; a split ring collar assembly movably coupled to theexterior of the tubular support member comprising: a second tubularsupport body defining: N T-shaped slots for movably receivingcorresponding ones of the second T-shaped retaining members of theexpansion cone segments; and an L-shaped retaining member coupled to thesecond tubular support body; a first drag block assembly movably coupledto the tubular support member that comprises: a first drag block bodydefining: a slot for receiving and mating with the L-shaped retainingmember of the split ring collar; and a first J-shaped slot for receivingthe first lug; and one or more first drag blocks coupled to the firstdrag block body; a second drag block assembly movably coupled to thetubular support member that comprises: a second drag block bodydefining: a second J-shaped slot for receiving the second lug; and oneor more second drag blocks coupled to the second drag block body; andfirst and second packer cups coupled to the tubular support memberbetween the first and second drag block assemblies.
 2. An apparatus forradially expanding a tubular member, comprising: a tubular supportmember comprising: a first tubular support body defining a longitudinalpassage; a first flange coupled to the first tubular support body; asecond flange coupled to the first tubular support body; a first taperedflange coupled to the first tubular support body; a second taperedflange coupled to the first tubular support body; and an expansion conesupport body coupled to the first tubular support body comprising: anN-sided tapered tubular support member; wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot; Nexpansion cone segments movably coupled to the expansion cone supportbody, each comprising: an expansion cone segment body including arcuateconical outer surfaces; a first T-shaped retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a second T-shaped retaining membercoupled to the expansion cone segment body; a split ring collar movablycoupled to the exterior of the tubular support member comprising: asecond tubular support body that defines: N T-shaped slots for movablyreceiving corresponding ones of the second T-shaped retaining members ofthe expansion cone segments; and an L-shaped retaining member coupled tothe second tubular support body; a first collet assembly movably coupledto the tubular support member that comprises: a first tubular sleevedefining: a slot for receiving and mating with the L-shaped retainingmember of the split ring collar; a first counterbore for receiving thefirst flange; and a first radial passage; a first spring received withinthe first counterbore; a first retaining ring received within the firstcounterbore; a first load transfer pin coupled to the first retainingring and extending through the first radial passage; a second tubularsleeve coupled to the first load transfer pin; a first resilient colletcoupled to the second tubular sleeve and positioned above the firsttapered flange; and a third tubular sleeve coupled to the firstresilient collet; a second collet assembly movably coupled to thetubular support member that comprises: a fourth tubular sleeve defining:a second counterbore for receiving the second flange; and a secondradial passage; a second spring received within the second counterbore;a second retaining ring received within the second counterbore; a secondload transfer pin coupled to the second retaining ring and extendingthrough the second radial passage; a fifth tubular sleeve coupled to thesecond load transfer pin; a second resilient collet coupled to the fifthtubular sleeve and positioned above the second tapered flange; and asixth tubular sleeve coupled to the second resilient collet; and firstand second packer cups coupled to the tubular support member between thefirst and second collet assemblies.
 3. An apparatus for radiallyexpanding a tubular member, comprising: a tubular support membercomprising: a first tubular support body defining a longitudinalpassage; a first radial passage defined in the first tubular supportbody fluidicly coupled to the longitudinal passage; a first flangecoupled to the first tubular support body; a second flange coupled tothe first tubular support body; a first tapered flange coupled to thefirst tubular support body; a second tapered flange coupled to the firsttubular support body; and an expansion cone support body coupled to thefirst tubular support body comprising: an N-sided tapered tubularsupport member; wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot; N expansion cone segmentsmovably coupled to the expansion cone support body, each comprising: anexpansion cone segment body including arcuate conical outer surfaces; afirst T-shaped retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody; and a second T-shaped retaining member coupled to the expansioncone segment body; a split ring collar movably coupled to the exteriorof the tubular support member comprising: a second tubular support bodydefining: N T-shaped slots for movably receiving corresponding ones ofthe second T-shaped retaining members of the expansion cone segments;and an L-shaped retaining member coupled to the second tubular supportbody; a first dog assembly movably coupled to the tubular support memberthat comprises: a first tubular sleeve defining: a slot for receivingand mating with the L-shaped retaining member of the split ring collar;a first counterbore for receiving the first flange; and a second radialpassage; a first spring received within the first counterbore; a firstretaining ring received within the first counterbore; a first loadtransfer pin coupled to the first retaining ring and extending throughthe second radial passage; a second tubular sleeve coupled to the firstload transfer pin defining: a second counterbore for receiving the firsttubular sleeve; a first resilient dog coupled to the second tubularsleeve and positioned adjacent to the first tapered flange; a second dogassembly movably coupled to the tubular support member that comprises: athird tubular sleeve defining: a second counterbore for receiving thesecond flange; a third radial passage; and a fourth radial passagefluidicly coupled to the first radial passage; a second spring receivedwithin the second counterbore; a second retaining ring received withinthe second counterbore; a second load transfer pin coupled to the secondretaining ring and extending through the third radial passage; a fourthtubular sleeve coupled to the second toad transfer pin; a secondresilient dog coupled to the fourth tubular sleeve and positionedadjacent to the second tapered flange; and first and second packer cupscoupled to the tubular support member between the first and second dogassemblies.
 4. An apparatus for radially expanding a tubular member,comprising: a tubular support member comprising: a first tubular supportbody defining a longitudinal passage including a throat passage; a firstradial passage defined in the first tubular support body fluidiclycoupled to the longitudinal passage; a first flange coupled to the firsttubular support body; a second flange coupled to the first tubularsupport body defining: a second radial passage defined in the secondflange fluidicly coupled to the longitudinal passage; a tapered flangecoupled to the first tubular support body; and an expansion cone supportbody coupled to the first tubular support body comprising: an N-sidedtapered tubular support member; wherein each side of the multi-sidedtapered tubular support member defines a T-shaped slot; N expansion conesegments movably coupled to the expansion cone support body, eachcomprising: an expansion cone segment body including arcuate conicalouter surfaces; a first T-shaped retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a second T-shaped retaining membercoupled to the expansion cone segment body; a split ring collar movablycoupled to the exterior of the tubular support member comprising: asecond tubular support body defining: N T-shaped slots for movablyreceiving corresponding ones of the second T-shaped retaining members ofthe expansion cone segments; and an L-shaped retaining member coupled tothe second tubular support body; a dog assembly movably coupled to thetubular support member that comprises: a first tubular sleeve defining:a slot for receiving and mating with the L-shaped retaining member ofthe split ring collar; a first counterbore for receiving the firstflange; and a third radial passage; a spring received within the firstcounterbore; a retaining ring received within the first counterbore; aload transfer pin coupled to the retaining ring and extending throughthe third radial passage; a second tubular sleeve coupled to the firstload transfer pin that defines: a first counterbore for receiving thefirst tubular sleeve; a second counterbore for receiving and mating withthe tapered flange; and comprises: a third flange defining: a thirdcounterbore for receiving the second flange; a fourth counterbore forreceiving the second flange; and a fourth radial passage; and aresilient dog coupled to the second tubular sleeve and positionedadjacent to the tapered flange; and first and second packer cups coupledto the tubular support member between the resilient dog and the thirdflange.
 5. An adjustable expansion cone assembly, comprising: a tubularsupport member comprising: a tubular support body; and an expansion conesupport body coupled to the tubular support body comprising: an N-sidedtapered tubular support member; wherein each side of the multi-sidedtapered tubular support member defines a T-shaped slot; N expansion conesegments movably coupled to the expansion cone support body, eachcomprising: an expansion cone segment body including arcuate conicalouter surfaces; a first T-shaped retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a second T-shaped retaining membercoupled to the expansion cone segment body; a split ring collar movablycoupled to the exterior of the tubular support member comprising: asecond tubular support body defining: N T-shaped slots for movablyreceiving corresponding ones of the second T-shaped retaining members ofthe expansion cone segments; and an L-shaped retaining member coupled tothe second tubular support body; and a tubular actuating sleeve movablycoupled to the tubular support member that comprises: a third tubularsupport body defining: a slot for receiving and mating with the L-shapedretaining member of the split ring collar.
 6. An adjustable expansioncone assembly, comprising: a tubular support member comprising: a firsttubular support body; and an expansion cone support body coupled to thetubular support body comprising: a tapered tubular support memberdefining N stepped slots; an expansion cone assembly movably coupled tothe tubular support member comprising: a second tubular support bodymovably coupled to the first tubular support body defining an L-shapedslot; and N expansion cone segments extending from the second tubularsupport member, each expansion cone segment comprising: a resilientcollet coupled to the second tubular support member; an expansion conesegment body coupled to the resilient collet including arcuate conicalouter surfaces; and a retaining member coupled to the expansion conesegment body for movably coupling the expansion cone segment body to acorresponding one of the stepped slots of the expansion cone supportbody; a split ring collar movably coupled to the exterior of the tubularsupport member comprising: a third tubular support body; a firstL-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body of theexpansion cone assembly; and a second L-shaped retaining member coupledto the third tubular body; and a tubular actuating sleeve movablycoupled to the tubular support member that comprises: a third tubularsupport body defining: a slot for receiving and mating with the secondL-shaped retaining member of the split ring collar.
 7. An adjustableexpansion cone assembly, comprising: a tubular support membercomprising: a first tubular support body; and expansion cone supportbody coupled to the tubular support body comprising: a tapered tubularsupport member defining N slots; an expansion cone assembly movablycoupled to the tubular support member comprising: a second tubularsupport body movably coupled to the first tubular support body definingan L-shaped slot; and N expansion cone segments extending from thesecond tubular support member, each expansion cone segment comprising: aresilient collet coupled to the second tubular support member; anexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces; and a retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body; a split ring collar movably coupled to the exterior of thetubular support member comprising: a third tubular support body; a first1-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body; and asecond L-shaped retaining member coupled to the third tubular supportbody; and a tubular actuating sleeve movably coupled to the tubularsupport member that comprises: a third tubular support body defining: aslot for receiving and mating with the second L-shaped retaining memberof the split ring collar.
 8. An adjustable expansion cone assembly,comprising: a tubular support member comprising: a first tubular supportbody; and an expansion cone support body coupled to the tubular supportbody comprising: a tapered tubular support member defining N slots; anexpansion cone assembly movably coupled to the tubular support membercomprising: a second tubular support body movably coupled to the firsttubular support body defining an L-shaped slot; and N/2 first expansioncone segments extending from the second tubular support member, eachfirst expansion cone segment comprising: a first resilient colletcoupled to the second tubular support member; a first expansion conesegment body coupled to the resilient collet including arcuate conicalouter surfaces; and a first retaining member coupled to the expansioncone segment body for movably coupling the expansion cone segment bodyto a corresponding one of the slots of the expansion cone support body;N/2 second expansion cone segments extending from the second tubularsupport member, each second expansion cone segment comprising: a secondresilient collet coupled to the second tubular support member; a secondexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces; and a second retaining member coupled tothe expansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body; wherein the second expansion cone segments overlap and areinterleaved with the first expansion cone segments; a split ring collarmovably coupled to the exterior of the tubular support membercomprising: a third tubular support body; a first L-shaped retainingmember coupled to the third tubular support body for mating withL-shaped slot of the second tubular support body; and a second L-shapedretaining member coupled to the third tubular support body; and atubular actuating sleeve movably coupled to the tubular support memberthat comprises: a third tubular support body defining: a slot forreceiving and mating with the second L-shaped retaining member of thesplit ring collar.
 9. An adjustable expansion cone assembly, comprising:a tubular support member comprising: a first tubular support body; andan expansion cone support body coupled to the first tubular support bodycomprising: an N-sided tapered tubular support member; wherein each sideof the multi-sided tapered tubular support member defines a T-shapedslot; N/2 first expansion cone segments movably coupled to the expansioncone support body, each comprising: a first expansion cone segment bodyincluding arcuate conical outer surfaces; a first T-shaped retainingmember coupled to the first expansion cone segment body for movablycoupling the first expansion cone segment body to a corresponding one ofthe T-shaped slots of the expansion cone support body; and a secondT-shaped retaining member coupled to the first expansion cone segmentbody; N/2 second expansion cone segments movably coupled to theexpansion cone support body, each comprising: a second expansion conesegment body including arcuate conical outer surfaces; a third T-shapedretaining member coupled to the second expansion cone segment body formovably coupling the second expansion cone segment body to acorresponding one of the T-shaped slots of the expansion cone supportbody; and a fourth T-shaped retaining member coupled to the expansioncone segment body; wherein the first and second expansion cone segmentsare interleaved; wherein the first expansion cone segment bodies arecomplementary shaped with respect to the second expansion cone segmentbodies; a split ring collar assembly movably coupled to the exterior ofthe tubular support member comprising: a second tubular support bodydefining: N T-shaped slots for movably receiving corresponding ones ofthe second and fourth T-shaped retaining members of the interleavedfirst and second expansion cone segments; and an L-shaped retainingmember coupled to the second tubular support body; and a tubularactuating sleeve movably coupled to the tubular support member thatcomprises: a third tubular support body defining: a slot for receivingand mating with the L-shaped retaining member of the split ring collar.10. An apparatus for radially expanding a tubular member, comprising: atubular support member comprising: a first tubular support body defininga longitudinal passage; a first lug coupled to and extending from thefirst tubular support body in the radial direction; and a second lugcoupled to and extending from the first tubular support body in theradial direction; an adjustable expansion cone assembly movably coupledto the tubular support member; a first drag block assembly movablycoupled to the tubular support member that comprises: a first drag blockbody coupled to the adjustable expansion cone assembly defining: a firstJ-shaped slot for receiving the first lug; and one or more first dragblocks coupled to the first drag block body; a second drag blockassembly movably coupled to the tubular support member that comprises: asecond drag block body defining: a second J-shaped slot for receivingthe second lug; and one or more second drag blocks coupled to the seconddrag block body; and first and second packer cups coupled to the tubularsupport member between the first and second drag block assemblies. 11.The apparatus of claim 10, wherein the tubular support member furthercomprises: an expansion cone support body coupled to the first tubularsupport body comprising: an N-sided tapered tubular support member;wherein each side of the multi-sided tapered tubular support memberdefines a T-shaped slot; wherein the adjustable expansion cone assemblycomprises: N expansion cone segments movably coupled to the expansioncone support body, each comprising: an expansion cone segment bodyincluding arcuate conical outer surfaces; a first T-shaped retainingmember coupled to the expansion cone segment body for movably couplingthe expansion cone segment body to a corresponding one of the T-shapedslots of the expansion cone support body; and a second T-shapedretaining member coupled to the expansion cone segment body; and a splitring collar movably coupled to the exterior of the tubular supportmember comprising: a second tubular support body defining: N T-shapedslots for movably receiving corresponding ones of the second T-shapedretaining members of the expansion cone segments; and an L-shapedretaining member coupled to the second tubular support body; and whereinthe first drag block body further defines: a slot for receiving andmating with the L-shaped retaining member of the split ring collar. 12.The apparatus of claim 10, wherein the tubular support member furthercomprises: an expansion cone support body coupled to the tubular supportbody comprising: a tapered tubular support member defining N steppedslots; wherein the adjustable expansion cone assembly comprises: anexpansion cone assembly movably coupled to the tubular support membercomprising: a second tubular support body movably coupled to the firsttubular support body defining an L-shaped slot; and N expansion conesegments extending from the second tubular support member, eachexpansion cone segment comprising: a resilient collet coupled to thesecond tubular support member; an expansion cone segment body coupled tothe resilient collet including arcuate conical outer surfaces; and aretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of thestepped slots of the expansion cone support body; and a split ringcollar movably coupled to the exterior of the tubular support membercomprising: a third tubular support body: a first L-shaped retainingmember coupled to the third tubular support body for mating with theL-shaped slot of the second tubular support body; and a second L-shapedretaining member coupled to the third tubular support member; whereinthe first drag block body further defines: a slot for receiving andmating with the second t-shaped retaining member of the split ringcollar.
 13. The apparatus of claim 10, wherein the tubular supportmember further comprises: an expansion cone support body coupled to thefirst tubular support body comprising: a tapered tubular support memberdefining N slots; wherein the adjustable expansion cone assemblycomprises: an expansion cone assembly movably coupled to the tubularsupport member comprising: a second tubular support body movably coupledto the first tubular support body defining an L-shaped slot; and Nexpansion cone segments extending from the second tubular supportmember, each expansion cone segment comprising: a resilient colletcoupled to the second tubular support member; an expansion cone segmentbody coupled to the resilient collet including arcuate conical outersurfaces; and a retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the slots of the expansion cone support body; and asplit ring collar movably coupled to the exterior of the tubular supportmember comprising: a third tubular support body; a first L-shapedretaining member coupled to the third tubular support body for matingwith L-shaped slot of the second tubular support body; and a secondL-shaped retaining member coupled to the third tubular support body;wherein the first drag block body further defines: a slot for receivingand mating with the second L-shaped retaining member of the split ringcollar.
 14. The apparatus of claim 10, wherein the tubular supportmember further comprises: an expansion cone support body coupled to thetubular support body comprising: a tapered tubular support memberdefining N slots; wherein the adjustable expansion cone assemblycomprises: an expansion cone assembly movably coupled to the tubularsupport member comprising: a second tubular support body movably coupledto the first tubular support body defining an L-shaped slot; and N/2first expansion cone segments extending from the second tubular supportmember, each first expansion cone segment comprising: a first resilientcollet coupled to the second tubular support member; a first expansioncone segment body coupled to the resilient collet including arcuateconical outer surfaces; and a first retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body; N/2 second expansion cone segments extending from thesecond tubular support member, each second expansion cone segmentcomprising: a second resilient collet coupled to the second tubularsupport member; a second expansion cone segment body coupled to theresilient collet including arcuate conical outer surfaces; and a secondretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theslots of the expansion cone support body; wherein the second expansioncone segments overlap and are interleaved with the first expansion conesegments; and a split ring collar movably coupled to the exterior of thetubular support member comprising: a third tubular support body; a firstL-shaped retaining member coupled to the third tubular support body formating with the 1-shaped slot of the second tubular support body; and asecond L-shaped retaining member coupled to the third tubular supportbody; wherein the first drag block body further defines: a slot forreceiving and mating with the second L-shaped retaining member of thesplit ring collar.
 15. The apparatus of claim 10, wherein the tubularsupport member further comprises: an expansion cone support body coupledto the first tubular support body comprising: an N-sided tapered tubularsupport member; wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot; wherein the adjustable expansioncone assembly comprises: N12 first expansion cone segments movablycoupled to the expansion cone support body, each comprising: a firstexpansion cone segment body including arcuate conical outer surfaces; afirst T-shaped retaining member coupled to the first expansion conesegment body for movably coupling the first expansion cone segment bodyto a corresponding one of the T-shaped slots of the expansion conesupport body; and a second T-shaped retaining member coupled to thefirst expansion cone segment body; N/2 second expansion cone segmentsmovably coupled to the expansion cone support body, each comprising: asecond expansion cone segment body including arcuate conical outersurfaces; a third T-shaped retaining member coupled to the secondexpansion cone segment body for movably coupling the second expansioncone segment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a fourth T-shaped retaining membercoupled to the expansion cone segment body; wherein the first and secondexpansion cone segments are interleaved; wherein the first expansioncone segment bodies are complementary shaped with respect to the secondexpansion cone segment bodies; and a split ring collar assembly movablycoupled to the exterior of the tubular support member comprising: asecond tubular support body defining: N T-shaped slots for movablyreceiving corresponding ones of the second and fourth T-shaped retainingmembers of the interleaved first and second expansion cone segments; andan L-shaped retaining member coupled to the second tubular support body;and wherein the first drag block body further defines: a slot forreceiving and mating with the L-shaped retaining member of the splitring collar.
 16. An apparatus for radially expanding a tubular member,comprising: a tubular support member comprising: a first tubular supportbody defining a longitudinal passage; a first flange coupled to thefirst tubular support body; a second flange coupled to the first tubularsupport body; a first tapered flange coupled to the first tubularsupport body; and a second tapered flange coupled to the first tubularsupport body; an adjustable expansion cone assembly movably coupled tothe tubular support member; a first collet assembly movably coupled tothe tubular support member that comprises: a first tubular sleevecoupled to the adjustable expansion cone assembly and defining: a firstcounterbore for receiving the first flange; and a first radial passage;a first spring received within the first counterbore; a first retainingring received within the first counterbore; a first load transfer pincoupled to the first retaining ring and extending through the firstradial passage; a second tubular sleeve coupled to the first loadtransfer pin; a first resilient collet coupled to the second tubularsleeve and positioned above the first tapered flange; and a thirdtubular sleeve coupled to the first resilient collet; a second colletassembly movably coupled to the tubular support member that comprises: afourth tubular sleeve defining: a second counterbore for receiving thesecond flange; and a second radial passage; a second spring receivedwithin the second counterbore; a second retaining ring received withinthe second counterbore; a second load transfer pin coupled to the secondretaining ring and extending through the second radial passage; a fifthtubular sleeve coupled to the second load transfer pin; a secondresilient collet coupled to the fifth tubular sleeve and positionedabove the second tapered flange; and a sixth tubular sleeve coupled tothe second resilient collet; and first and second packer cups coupled tothe tubular support member between the first and second colletassemblies.
 17. The apparatus of claim 16, wherein the tubular supportmember further comprises: an expansion cone support body coupled to thefirst tubular support body comprising: an N-sided tapered tubularsupport member; wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot; wherein the adjustable expansioncone assembly comprises: N expansion cone segments movably coupled tothe expansion cone support body, each comprising: an expansion conesegment body including arcuate conical outer surfaces; a first T-shapedretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theT-shaped slots of the expansion cone support body; and a second T-shapedretaining member coupled to the expansion cone segment body; and a splitring collar movably coupled to the exterior of the tubular supportmember comprising: a second tubular support body defining: N T-shapedslots for movably receiving corresponding ones of the second T-shapedretaining members of the expansion cone segments; and an L-shapedretaining member coupled to the second tubular support body; and whereinthe first tubular sleeve of the first collet assembly further defines: aslot for receiving and mating with the L-shaped retaining member of thesplit ring collar.
 18. The apparatus of claim 16, wherein the tubularsupport member further comprises: an expansion cone support body coupledto the tubular support body comprising: a tapered tubular support memberdefining N stepped slots; wherein the adjustable expansion cone assemblycomprises: an expansion cone assembly movably coupled to the tubularsupport member comprising: a second tubular support body movably coupledto the first tubular support body defining an L-shaped slot; and Nexpansion cone segments extending from the second tubular supportmember, each expansion cone segment comprising: a resilient colletcoupled to the second tubular support member; an expansion cone segmentbody coupled to the resilient collet including arcuate conical outersurfaces; and a retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the stepped slots of the expansion cone supportbody; and a split ring collar movably coupled to the exterior of thetubular support member comprising: a third tubular support body: a firstL-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body; and asecond L-shaped retaining member coupled to the third tubular supportmember; wherein the first tubular sleeve of the first collet assemblyfurther defines: a slot for receiving and mating with the secondL-shaped retaining member of the split ring collar.
 19. The apparatus ofclaim 16, wherein the tubular support member further comprises: anexpansion cone support body coupled to the first tubular support bodycomprising: a tapered tubular support member defining N slots; whereinthe adjustable expansion cone assembly comprises: an expansion coneassembly movably coupled to the tubular support member comprising: asecond tubular support body movably coupled to the first tubular supportbody defining an L-shaped slot; and N expansion cone segments extendingfrom the second tubular support member, each expansion cone segmentcomprising: a resilient collet coupled to the second tubular supportmember; an expansion cone segment body coupled to the resilient colletincluding arcuate conical outer surfaces; and a retaining member coupledto the expansion cone segment body for movably coupling the expansioncone segment body to a corresponding one of the slots of the expansioncone support body; and a split ring collar movably coupled to theexterior of the tubular support member comprising: a third tubularsupport body; a first L-shaped retaining member coupled to the thirdtubular support body for mating with L-shaped slot of the second tubularsupport body; and a second L-shaped retaining member coupled to thethird tubular support body; wherein the first tubular sleeve of thefirst collet assembly further defines: a slot for receiving and matingwith the second L-shaped retaining member of the split ring collar. 20.The apparatus of claim 16, wherein the tubular support member furthercomprises: an expansion cone support body coupled to the tubular supportbody comprising: a tapered tubular support member defining N slots;wherein the adjustable expansion cone assembly comprises: an expansioncone assembly movably coupled to the tubular support member comprising:a second tubular support body movably coupled to the first tubularsupport body defining an L-shaped slot; and N/2 first expansion conesegments extending from the second tubular support member, each firstexpansion cone segment comprising: a first resilient collet coupled tothe second tubular support member; a first expansion cone segment bodycoupled to the resilient collet including arcuate conical outersurfaces; and a first retaining member coupled to the expansion conesegment body for movably coupling the expansion cone segment body to acorresponding one of the slots of the expansion cone support body; N/2second expansion cone segments extending from the second tubular supportmember, each second expansion cone segment comprising: a secondresilient collet coupled to the second tubular support member; a secondexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces; and a second retaining member coupled tothe expansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body; wherein the second expansion cone segments overlap and areinterleaved with the first expansion cone segments; and a split ringcollar movably coupled to the exterior of the tubular support membercomprising: a third tubular support body; a first L-shaped retainingmember coupled to the third tubular support body for mating with theL-shaped slot of the second tubular support body; and a second L-shapedretaining member coupled to the third tubular support body; wherein thefirst tubular sleeve of the first collet assembly further defines: aslot for receiving and mating with the second L-shaped retaining memberof the split ring collar.
 21. The apparatus of claim 16, wherein thetubular support member further comprises: an expansion cone support bodycoupled to the first tubular support body comprising: an N-sided taperedtubular support member; wherein each side of the multi-sided taperedtubular support member defines a T-shaped slot; wherein the adjustableexpansion cone assembly comprises: N/2 first expansion cone segmentsmovably coupled to the expansion cone support body, each comprising: afirst expansion cone segment body including arcuate conical outersurfaces; a first T-shaped retaining member coupled to the firstexpansion cone segment body for movably coupling the first expansioncone segment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a second T-shaped retaining membercoupled to the first expansion cone segment body; N/2 second expansioncone segments movably coupled to the expansion cone support body, eachcomprising: a second expansion cone segment body including arcuateconical outer surfaces; a third T-shaped retaining member coupled to thesecond expansion cone segment body for movably coupling the secondexpansion cone segment body to a corresponding one of the T-shaped slotsof the expansion cone support body; and a fourth T-shaped retainingmember coupled to the expansion cone segment body; wherein the first andsecond expansion cone segments are interleaved; wherein the firstexpansion cone segment bodies are complementary shaped with respect tothe second expansion cone segment bodies; and a split ring collarassembly movably coupled to the exterior of the tubular support membercomprising: a second tubular support body defining: N T-shaped slots formovably receiving corresponding ones of the second and fourth T-shapedretaining members of the interleaved first and second expansion conesegments; and an L-shaped retaining member coupled to the second tubularsupport body; and wherein the first tubular sleeve of the first colletassembly further defines: a slot for receiving and mating with theL-shaped retaining member of the split ring collar.
 22. An apparatus forradially expanding a tubular member, comprising: a tubular supportmember comprising: a first tubular support body defining a longitudinalpassage; a first radial passage defined in the first tubular supportbody fluidicly coupled to the longitudinal passage; a first flangecoupled to the first tubular support body; a second flange coupled tothe first tubular support body; a first tapered flange coupled to thefirst tubular support body; and a second tapered flange coupled to thefirst tubular support body; an adjustable expansion cone assemblymovably coupled to the tubular support member; a first dog assemblymovably coupled to the tubular support member that comprises: a firsttubular sleeve coupled to the adjustable expansion cone assemblydefining: a first counterbore for receiving the first flange; and asecond radial passage; a first spring received within the firstcounterbore; a first retaining ring received within the firstcounterbore; a first load transfer pin coupled to the first retainingring and extending through the second radial passage; a second tubularsleeve coupled to the first load transfer pin defining: a secondcounterbore for receiving the first tubular sleeve; a first resilientdog coupled to the second tubular sleeve and positioned adjacent to thefirst tapered flange; a second dog assembly movably coupled to thetubular support member that comprises: a third tubular sleeve defining:a second counterbore for receiving the second flange; a third radialpassage; and a fourth radial passage fluidicly coupled to the firstradial passage; a second spring received within the second counterbore;a second retaining ring received within the second counterbore; a secondload transfer pin coupled to the second retaining ring and extendingthrough the third radial passage; a fourth tubular sleeve coupled to thesecond load transfer pin; a second resilient dog coupled to the fourthtubular sleeve and positioned adjacent to the second tapered flange; andfirst and second packer cups coupled to the tubular support memberbetween the first and second dog assemblies.
 23. The apparatus of claim22, wherein the tubular support member further comprises: an expansioncone support body coupled to the first tubular support body comprising:an N-sided tapered tubular support member; wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot;wherein the adjustable expansion cone assembly comprises: N expansioncone segments movably coupled to the expansion cone support body, eachcomprising: an expansion cone segment body including arcuate conicalouter surfaces; a first T-shaped retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a second T-shaped retaining membercoupled to the expansion cone segment body; and a split ring collarmovably coupled to the exterior of the tubular support membercomprising: a second tubular support body defining: N T-shaped slots formovably receiving corresponding ones of the second T-shaped retainingmembers of the expansion cone segments; and an L-shaped retaining membercoupled to the second tubular support body; and wherein the firsttubular sleeve of the first dog assembly further defines: a slot forreceiving and mating with the L-shaped retaining member of the splitring collar.
 24. The apparatus of claim 22, wherein the tubular supportmember further comprises: an expansion cone support body coupled to thetubular support body comprising: a tapered tubular support memberdefining N stepped slots; wherein the adjustable expansion cone assemblycomprises: an expansion cone assembly movably coupled to the tubularsupport member comprising: a second tubular support body movably coupledto the first tubular support body defining an L-shaped slot; and Nexpansion cone segments extending from the second tubular supportmember, each expansion cone segment comprising: a resilient colletcoupled to the second tubular support member; an expansion cone segmentbody coupled to the resilient collet including arcuate conical outersurfaces; and a retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the stepped slots of the expansion cone supportbody; and a split ring collar movably coupled to the exterior of thetubular support member comprising: a third tubular support body: a firstL-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body; and asecond L-shaped retaining member coupled to the third tubular supportmember; and wherein the first tubular sleeve of the first dog assemblyfurther defines: a slot for receiving and mating with the secondL-shaped retaining member of the split ring collar.
 25. The apparatus ofclaim 22, wherein the tubular support member further comprises: anexpansion cone support body coupled to the first tubular support bodycomprising: a tapered tubular support member defining N slots; whereinthe adjustable expansion cone assembly comprises: an expansion coneassembly movably coupled to the tubular support member comprising: asecond tubular support body movably coupled to the first tubular supportbody defining an L-shaped slot; and N expansion cone segments extendingfrom the second tubular support member, each expansion cone segmentcomprising: a resilient collet coupled to the second tubular supportmember; an expansion cone segment body coupled to the resilient colletincluding arcuate conical outer surfaces; and a retaining member coupledto the expansion cone segment body for movably coupling the expansioncone segment body to a corresponding one of the slots of the expansioncone support body; and a split ring collar movably coupled to theexterior of the tubular support member comprising: a third tubularsupport body; a first L-shaped retaining member coupled to the thirdtubular support body for mating with L-shaped slot of the second tubularsupport body; and a second L-shaped retaining member coupled to thethird tubular support body; and wherein the first tubular sleeve of thefirst dog assembly further defines: a slot for receiving and mating withthe second L-shaped retaining member of the split ring collar.
 26. Theapparatus of claim 22, wherein the tubular support member furthercomprises: an expansion cone support body coupled to the tubular supportbody comprising: a tapered tubular support member defining N slots;wherein the adjustable expansion cone assembly comprises: an expansioncone assembly movably coupled to the tubular support member comprising:a second tubular support body movably coupled to the first tubularsupport body defining an L-shaped slot; and N/2 first expansion conesegments extending from the second tubular support member, each firstexpansion cone segment comprising: a first resilient collet coupled tothe second tubular support member; a first expansion cone segment bodycoupled to the resilient collet including arcuate conical outersurfaces; and a first retaining member coupled to the expansion conesegment body for movably coupling the expansion cone segment body to acorresponding one of the slots of the expansion cone support body; N/2second expansion cone segments extending from the second tubular supportmember, each second expansion cone segment comprising: a secondresilient collet coupled to the second tubular support member; a secondexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces; and a second retaining member coupled tothe expansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body; wherein the second expansion cone segments overlap and areinterleaved with the first expansion cone segments; and a split ringcollar movably coupled to the exterior of the tubular support membercomprising: a third tubular support; a first L-shaped retaining membercoupled to the third tubular support body for mating with the L-shapedslot of the second tubular support body; and a second L-shaped retainingmember coupled to the third tubular support body; and wherein the firsttubular sleeve of the first dog assembly further defines: a slot forreceiving and mating with the second L-shaped retaining member of thesplit ring collar.
 27. The apparatus of claim 22, wherein the tubularsupport member further comprises: an expansion cone support body coupledto the first tubular support body comprising: an N-sided tapered tubularsupport member; wherein each side of the multi-sided tapered tubularsupport member defines a T-shaped slot; wherein the adjustable expansioncone assembly comprises: N/2 first expansion cone segments movablycoupled to the expansion cone support body, each comprising: a firstexpansion cone segment body including arcuate conical outer surfaces; afirst T-shaped retaining member coupled to the first expansion conesegment body for movably coupling the first expansion cone segment bodyto a corresponding on of the T-shaped slots of the expansion conesupport body; and a second T-shaped retaining member coupled to thefirst expansion cone segment body; N/2 second expansion cone segmentsmovably coupled to the expansion cone support body, each comprising: asecond expansion cone segment body including arcuate conical outersurfaces; a third T-shaped retaining member coupled to the secondexpansion cone segment body for movably coupling the second expansioncone segment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a fourth T-shaped retaining membercoupled to the expansion cone segment body; wherein the first and secondexpansion cone segments are interleaved; wherein the first expansioncone segment bodies are complementary shaped with respect to the secondexpansion cone segment bodies; and a split ring collar assembly movablycoupled to the exterior of the tubular support member comprising: asecond tubular support body defining: N T-shaped slots for movablyreceiving corresponding ones of the second and fourth T-shaped retainingmembers of the interleaved first and second expansion cone segments; andan L-shaped retaining member coupled to the second tubular support body;and wherein the first tubular sleeve of the first dog assembly furtherdefines: a slot for receiving and mating with the L-shaped retainingmember of the split ring collar.
 28. An apparatus for radially expandinga tubular member, comprising: a tubular support member comprising: afirst tubular support body defining a longitudinal passage including athroat passage; a first radial passage defined in the first tubularsupport body fluidicly coupled to the longitudinal passage; a firstflange coupled to the first tubular support body; a second flangecoupled to the first tubular support body defining: a second radialpassage defined in the second flange fluidicly coupled to thelongitudinal passage; and an adjustable expansion cone assembly movablycoupled to the tubular support member; a dog assembly movably coupled tothe tubular support member that comprises: a first tubular sleevecoupled to the adjustable expansion cone assembly defining: a firstcounterbore for receiving the first flange; and a third radial passage;a spring received within the first counterbore; a retaining ringreceived within the first counterbore; a load transfer pin coupled tothe retaining ring and extending through the third radial passage; asecond tubular sleeve coupled to the first load transfer pin thatdefines: a first counterbore for receiving the first tubular sleeve; asecond counterbore for receiving and mating with the tapered flange; andcomprises: a third flange defining: a third counterbore for receivingthe second flange; a fourth counterbore for receiving the second flange;and a fourth radial passage; and a resilient dog coupled to the secondtubular sleeve and positioned adjacent to the tapered flange; and firstand second packer cups coupled to the tubular support member between theresilient dog and the third flange.
 29. The apparatus of claim 28,wherein the tubular support member further comprises: an expansion conesupport body coupled to the first tubular support body comprising: anN-sided tapered tubular support member; wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot;wherein the adjustable expansion cone assembly comprises: N expansioncone segments movably coupled to the expansion cone support body, eachcomprising: an expansion cone segment body including arcuate conicalouter surfaces; a first T-shaped retaining member coupled to theexpansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the T-shaped slots of theexpansion cone support body; and a second T-shaped retaining membercoupled to the expansion cone segment body; and a split ring collarmovably coupled to the exterior of the tubular support membercomprising: a second tubular support body defining: N T-shaped slots formovably receiving corresponding ones of the second T-shaped retainingmembers of the expansion cone segments; and an L-shaped retaining membercoupled to the second tubular support body; and wherein the firsttubular sleeve of the dog assembly further defines: a slot for receivingand mating with the L-shaped retaining member of the split ring collar.30. The apparatus of claim 28, wherein the tubular support memberfurther comprises: an expansion cone support body coupled to the tubularsupport body comprising: a tapered tubular support member defining Nstepped slots; wherein the adjustable expansion cone assembly comprises:an expansion cone assembly movably coupled to the tubular support membercomprising: a second tubular support body movably coupled to the firsttubular support body defining an L-shaped slot; and N expansion conesegments extending from the second tubular support member, eachexpansion cone segment comprising: a resilient collet coupled to thesecond tubular support member; an expansion cone segment body coupled tothe resilient collet including arcuate conical outer surfaces; and aretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of thestepped slots of the expansion cone support body; and a split ringcollar movably coupled to the exterior of the tubular support membercomprising: a third tubular support body: a first L-shaped retainingmember coupled to the third tubular support body for mating with theL-shaped slot of the second tubular support body; and a second L-shapedretaining member coupled to the third tubular support member; andwherein the first tubular sleeve of the dog assembly further defines: aslot for receiving and mating with the second L-shaped retaining memberof the split ring collar.
 31. The apparatus of claim 28, wherein thetubular support member further comprises: an expansion cone support bodycoupled to the first tubular support body comprising: a tapered tubularsupport member defining N slots; wherein the adjustable expansion coneassembly comprises: an expansion cone assembly movably coupled to thetubular support member comprising: a second tubular support body movablycoupled to the first tubular support body defining an L-shaped slot; andN expansion cone segments extending from the second tubular supportmember, each expansion cone segment comprising: a resilient colletcoupled to the second tubular support member; an expansion cone segmentbody coupled to the resilient collet including arcuate conical outersurfaces; and a retaining member coupled to the expansion cone segmentbody for movably coupling the expansion cone segment body to acorresponding one of the slots of the expansion cone support body; and asplit ring collar movably coupled to the exterior of the tubular supportmember comprising: a third tubular support body; a first L-shapedretaining member coupled to the third tubular support body for matingwith L-shaped slot of the second tubular support body; and a secondL-shaped retaining member coupled to the third tubular support body; andwherein the first tubular sleeve of the dog assembly further defines: aslot for receiving and mating with the second L-shaped retaining memberof the split ring collar.
 32. The apparatus of claim 28, wherein thetubular support member further comprises: an expansion cone support bodycoupled to the tubular support body comprising: a tapered tubularsupport member defining N slots; wherein the adjustable expansion coneassembly comprises: an expansion cone assembly movably coupled to thetubular support member comprising: a second tubular support body movablycoupled to the first tubular support body defining an L-shaped slot; andN/2 first expansion cone segments extending from the second tubularsupport member, each first expansion cone segment comprising: a firstresilient collet coupled to the second tubular support member; a firstexpansion cone segment body coupled to the resilient collet includingarcuate conical outer surfaces; and a first retaining member coupled tothe expansion cone segment body for movably coupling the expansion conesegment body to a corresponding one of the slots of the expansion conesupport body; N/2 second expansion cone segments extending from thesecond tubular support member, each second expansion cone segmentcomprising: a second resilient collet coupled to the second tubularsupport member; a second expansion cone segment body coupled to theresilient collet including arcuate conical outer surfaces; and a secondretaining member coupled to the expansion cone segment body for movablycoupling the expansion cone segment body to a corresponding one of theslots of the expansion cone support body; wherein the second expansioncone segments overlap and are interleaved with the first expansion conesegments; and a split ring collar movably coupled to the exterior of thetubular support member comprising: a third tubular support body; a firstL-shaped retaining member coupled to the third tubular support body formating with the L-shaped slot of the second tubular support body; and asecond L-shaped retaining member coupled to the third tubular supportbody; and wherein the first tubular sleeve of the dog assembly furtherdefines: a slot for receiving and mating with the second L-shapedretaining member of the split ring collar.
 33. The apparatus of claim28, wherein the tubular support member further comprises: an expansioncone support body coupled to the first tubular support body comprising:an N-sided tapered tubular support member; wherein each side of themulti-sided tapered tubular support member defines a T-shaped slot;wherein the adjustable expansion cone assembly comprises: N/2 firstexpansion cone segments movably coupled to the expansion cone supportbody, each comprising: a first expansion cone segment body includingarcuate conical outer surfaces; a first T-shaped retaining membercoupled to the first expansion cone segment body for movably couplingthe first expansion cone segment body to a corresponding one of theT-shaped slots of the expansion cone support body; and a second T-shapedretaining member coupled to the first expansion cone segment body; N/2second expansion cone segments movably coupled to the expansion conesupport body, each comprising: a second expansion cone segment bodyincluding arcuate conical outer surfaces; a third T-shaped retainingmember coupled to the second expansion cone segment body for movablycoupling the second expansion cone segment body to a corresponding oneof the T-shaped slots of the expansion cone support body; and a fourthT-shaped retaining member coupled to the expansion cone segment body;wherein the first and second expansion cone segments are interleaved;wherein the first expansion cone segment bodies are complementary shapedwith respect to the second expansion cone segment bodies; and a splitring collar assembly movably coupled to the exterior of the tubularsupport member comprising: a second tubular support body defining: NT-shaped slots for movably receiving corresponding ones of the secondand fourth T-shaped retaining members of the interleaved first andsecond expansion cone segments; and an L-shaped retaining member coupledto the second tubular support body; and wherein the first tubular sleeveof the dog assembly further defines: a slot for receiving and matingwith the L-shaped retaining member of the split ring collar.
 34. Anapparatus for radially expanding a tubular member, comprising: a tubularsupport member; an adjustable expansion cone assembly movably coupled tothe tubular support member; and means for adjusting the adjustableexpansion cone assembly.
 35. The apparatus of claim 34, wherein themeans for adjusting the adjustable expansion cone assembly comprises:frictional means for adjusting the adjustable expansion cone assembly.36. The apparatus of claim , wherein the means for adjusting theadjustable expansion cone assembly comprises: resilient means foradjusting the adjustable expansion cone assembly.
 37. An adjustableexpansion cone assembly, comprising: a tubular support member; anadjustable expansion cone movably coupled to the tubular support member,comprising: a plurality of expansion cone segments; and means forguiding the expansion cone segments on the tubular support member; andmeans for adjusting the adjustable expansion cone.
 38. The adjustableexpansion cone assembly of claim 37, wherein the adjustable expansioncone further comprises: means for interlocking the expansion conesegments.
 39. The adjustable expansion cone assembly of claim 37,wherein the means for adjusting the adjustable expansion cone comprises:resilient means for supporting the expansion cone segments.
 40. Theadjustable expansion cone assembly of claim 37, wherein the expansioncone segments include first and second interleaved groups of expansioncone segments.
 41. The adjustable expansion cone assembly of claim 40,wherein the means for adjusting the adjustable expansion cone comprises:means for displacing the first and second interleaved groups ofexpansion cone segments in opposite directions.
 42. A method ofplastically deforming and radially expanding an expandable tubularmember using an apparatus comprising a tubular support member, anadjustable expansion cone assembly movably coupled to the tubularsupport member, and an actuator movably coupled to the tubular supportmember for adjusting the adjustable expansion cone assembly, comprising:coupling a first end of the expandable tubular member to a tubularstructure; locking the actuator to the tubular support member of theapparatus; inserting the apparatus into the first end of the expandabletubular member; moving the actuator and the adjustable expansion coneassembly of the apparatus out of the second end of the expandabletubular member; reinserting the actuator of the apparatus into thesecond end of the expandable tubular member; unlocking the actuator fromthe tubular support member of the apparatus; rotating the actuatorrelative to the tubular support member of the apparatus; and increasingthe outside diameter of the adjustable expansion cone assembly by movingthe tubular support member relative to the actuator, the adjustableexpansion cone assembly, and the expandable tubular member; andplastically deforming and radially expanding the expandable tubularmember by moving the adjustable expansion cone assembly through theexpandable tubular member.
 43. The method of claim 42, wherein thetubular support member includes one or more tugs; wherein the actuatorincludes one or more corresponding retaining slots; and wherein lockingcomprises positioning the lugs into the corresponding retaining slots.44. The method of claim 42, wherein the tubular support member includesone or more lugs; wherein the actuator includes one or morecorresponding retaining slots; and wherein unlocking comprisespositioning the lugs out of engagement with corresponding retainingslots.
 45. The method of claim 42, wherein moving the tubular supportmember relative to the actuator, the adjustable expansion cone assembly,and the expandable tubular member comprises: the actuator frictionallyengaging the expandable tubular member.
 46. The method of claim 42,wherein moving the adjustable expansion cone assembly through theexpandable tubular member comprises: pulling the adjustable expansioncone through the expandable tubular member.
 47. The method of claim 42,further comprising: fluidicly sealing the interface between the tubularsupport member of the apparatus and the expandable tubular member;wherein moving the adjustable expansion cone assembly through theexpandable tubular member comprises: injecting a pressurized fluid intothe tubular support member.
 48. A method of plastically deforming andradially expanding an expandable tubular member using an apparatuscomprising a tubular support member, an adjustable expansion coneassembly movably coupled to the tubular support member, and an actuatormovably coupled to the tubular support member for adjusting theadjustable expansion cone assembly, comprising: coupling a first end ofthe expandable tubular member to a tubular structure; inserting theapparatus into the first end of the expandable tubular member in a firstdirection; displacing the actuator of the apparatus in a seconddirection opposite to the first direction; applying a resilient biasingforce to the adjustable expansion cone assembly in the second directionmoving the actuator and the adjustable expansion cone assembly of theapparatus out of the second end of the expandable tubular member;reinserting the actuator of the apparatus into the second end of theexpandable tubular member in the second direction; increasing theoutside diameter of the adjustable expansion cone assembly by displacingthe actuator and the adjustable expansion cone assembly relative to theexpandable tubular member in the first direction; and plasticallydeforming and radially expanding the expandable tubular member by movingthe adjustable expansion cone assembly through the expandable tubularmember in the second direction.
 49. The method of claim 48, whereindisplacing the actuator of the apparatus in the second directioncomprises: impacting the actuator with the first end of the expandabletubular member.
 50. The method of claim 48, wherein displacing theactuator and the adjustable expansion cone assembly relative to theexpandable tubular member in the first direction comprises: impactingthe actuator with the second end of the expandable tubular member. 51.The method of claim 48, wherein moving the adjustable expansion coneassembly through the expandable tubular member comprises: pulling theadjustable expansion cone through the expandable tubular member.
 52. Themethod of claim 48, further comprising: fluidicly sealing the interfacebetween the tubular support member of the apparatus and the expandabletubular member; wherein moving the adjustable expansion cone assemblythrough the expandable tubular member comprises: injecting a pressurizedfluid into the tubular support member.
 53. An adjustable expansion coneassembly, comprising: a plurality of expansion cone segments; means forguiding the expansion cone segments on a tapered body; and means forcontrollably displacing the expansion cone segments along the taperedbody.
 54. The assembly of claim 53, further comprising: means forresiliently guiding the expansion cone segments on the tapered body. 55.The assembly of claim 53, further comprising: means for interlocking theexpansion cone segments.
 56. The assembly of claim 53, furthercomprising: means for dividing the expansion cone segments into firstand second groups of expansion cone segments; and means for interleavingthe first and second groups of expansion cone segments.
 57. The assemblyof claim 56, further comprising: means for overlapping the first andsecond groups of expansion cone segments.
 58. The assembly of claim 56,wherein the means for controllably displacing the expansion conesegments along the tapered body comprises: means for displacing thefirst and second interleaved groups of expansion cone segments inopposite directions.
 59. An adjustable expansion cone assembly,comprising: a plurality of expansion cone segments; means for guidingthe expansion cone segments on a multi-sided tapered body; means forinterlocking the expansion cone segments; and means for controllablydisplacing the expansion cone segments along the tapered body.
 60. Anadjustable expansion cone assembly, comprising: a plurality of expansioncone segments; means for resiliently guiding the expansion cone segmentson a multi-sided tapered body; means for guiding each of the expansioncone segments on opposite sides in the circumferential direction; meansfor interlocking the expansion cone segments; and means for controllablydisplacing the expansion cone segments along the tapered body.
 61. Anadjustable expansion cone assembly, comprising: a plurality of expansioncone segments; means for dividing the expansion cone segments into firstand second groups of expansion cone segments; means for interleaving thefirst and second groups of expansion cone segments; means foroverlapping the first and second groups of expansion cone segments;means for resiliently guiding the expansion cone segments on amulti-sided tapered body; means for guiding each of the expansion conesegments on opposite sides in the circumferential direction; and meansfor controllably displacing the expansion cone segments along thetapered body.
 62. An adjustable expansion cone assembly, comprising: aplurality of expansion cone segments; means for dividing the expansioncone segments into first and second groups of expansion cone segments;means for interleaving the first and second groups of expansion conesegments; means for guiding the expansion cone segments on a multi-sidedtapered body; and means for controllably displacing the expansion conesegments along the tapered body while also relatively displacing thefirst and second groups of expansion cone segments in oppositedirections.
 63. An apparatus for plastically deforming and radiallyexpanding an expandable tubular member, comprising: a tubular supportmember; an adjustable expansion cone assembly movably coupled to thetubular support member; means for actuating the adjustable expansioncone assembly; means for locking the actuator to the tubular supportmember of the apparatus; means for unlocking the actuator from thetubular support member of the apparatus; means for increasing theoutside diameter of the adjustable expansion cone assembly by moving thetubular support member relative to the actuator, the adjustableexpansion cone assembly, and the expandable tubular member.
 64. Theapparatus of claim 63, wherein the tubular support member includes oneor more lugs; wherein the actuator includes one or more correspondingretaining slots; and wherein the means for locking comprises positioningthe lugs into the corresponding retaining slots.
 65. The apparatus ofclaim 63, wherein the tubular support member includes one or more lugs;wherein the actuator includes one or more corresponding retaining slots;and wherein the means for unlocking comprises positioning the lugs outof engagement with corresponding retaining slots.
 66. The apparatus ofclaim 63, further comprising: means for fluidicly sealing the interfacebetween the tubular support member of the apparatus and the expandabletubular member.
 67. An apparatus for plastically deforming and radiallyexpanding an expandable tubular member, comprising: a tubular supportmember; an adjustable expansion cone assembly movably coupled to thetubular support member; means for actuating the adjustable expansioncone assembly; means for displacing the actuator of the apparatus in afirst direction; means for applying a resilient biasing force to theadjustable expansion cone assembly when the actuator is displaced in thefirst direction; means for increasing the outside diameter of theadjustable expansion cone assembly by displacing the actuator and theadjustable expansion cone assembly relative to the expandable tubularmember in a second direction opposite to the first direction.
 68. Theapparatus of claim 67, wherein the means for displacing the actuator ofthe apparatus in the first direction comprises: means for impacting theactuator.
 69. The apparatus of claim 67, wherein the means fordisplacing the actuator and the adjustable expansion cone assemblyrelative to the expandable tubular member in the first directioncomprises: means for impacting the actuator.
 70. An apparatus forradially expanding a tubular member, comprising: a tubular supportmember; an adjustable expansion device movably coupled to the tubularsupport member; and means for adjusting the adjustable expansion device.71. The apparatus of claim 70, wherein the means for adjusting theadjustable expansion device comprises: frictional means for adjustingthe adjustable expansion device.
 72. The apparatus of claim 70, whereinthe means for adjusting the adjustable expansion device comprises:resilient means for adjusting the adjustable expansion device.
 73. Anadjustable expansion device, comprising: a tubular support member; anadjustable expansion device movably coupled to the tubular supportmember, comprising: a plurality of expansion segments; and means forguiding the expansion segments on the tubular support member; and meansfor adjusting the adjustable expansion device.
 74. The adjustableexpansion device of claim 73, wherein the adjustable expansion devicefurther comprises: means for interlocking the expansion segments. 75.The adjustable expansion device of claim 73, wherein the means foradjusting the adjustable expansion device comprises: resilient means forsupporting the expansion segments.
 76. The adjustable expansion deviceof claim 73, wherein the expansion segments include first and secondinterleaved groups of expansion segments.
 77. The adjustable expansiondevice of claim 76, wherein the means for adjusting the adjustableexpansion device comprises: means for displacing the first and secondinterleaved groups of expansion segments in opposite directions.
 78. Amethod of plastically deforming and radially expanding an expandabletubular member using an apparatus comprising a tubular support member,an adjustable expansion device movably coupled to the tubular supportmember, and an actuator movably coupled to the tubular support memberfor adjusting the adjustable expansion device, comprising: coupling afirst end of the expandable tubular member to a tubular structure;locking the actuator to the tubular support member of the apparatus;inserting the apparatus into the first end of the expandable tubularmember; moving the actuator and the adjustable expansion device of theapparatus out of the second end of the expandable tubular member;reinserting the actuator of the apparatus into the second end of theexpandable tubular member; unlocking the actuator from the tubularsupport member of the apparatus; rotating the actuator relative to thetubular support member of the apparatus; and increasing the outsidediameter of the adjustable expansion device by moving the tubularsupport member relative to the actuator, the adjustable expansiondevice, and the expandable tubular member; and plastically deforming andradially expanding the expandable tubular member by moving theadjustable expansion device through the expandable tubular member. 79.The method of claim 78, wherein the tubular support member includes oneor more lugs; wherein the actuator includes one or more correspondingretaining slots; and wherein locking comprises positioning the lugs intothe corresponding retaining slots.
 80. The method of claim 78, whereinthe tubular support member includes one or more lugs; wherein theactuator includes one or more corresponding retaining slots; and whereinunlocking comprises positioning the lugs out of engagement withcorresponding retaining slots.
 81. The method of claim 78, whereinmoving the tubular support member relative to the actuator, theadjustable expansion device, and the expandable tubular membercomprises: the actuator frictionally engaging the expandable tubularmember.
 82. The method of claim 78, wherein moving the adjustableexpansion device through the expandable tubular member comprises:pulling the adjustable expansion device through the expandable tubularmember.
 83. The method of claim 78, further comprising: fluidiclysealing the interface between the tubular support member of theapparatus and the expandable tubular member; wherein moving theadjustable expansion device through the expandable tubular membercomprises: injecting a pressurized fluid into the tubular supportmember.
 84. A method of plastically deforming and radially expanding anexpandable tubular member using an apparatus comprising a tubularsupport member, an adjustable expansion device movably coupled to thetubular support member, and an actuator movably coupled to the tubularsupport member for adjusting the adjustable expansion device,comprising: coupling a first end of the expandable tubular member to atubular structure; inserting the apparatus into the first end of theexpandable tubular member in a first direction; displacing the actuatorof the apparatus in a second direction opposite to the first direction;applying a resilient biasing force to the adjustable expansion device inthe second direction; moving the actuator and the adjustable expansiondevice of the apparatus out of the second end of the expandable tubularmember; reinserting the actuator of the apparatus into the second end ofthe expandable tubular member in the second direction; increasing theoutside diameter of the adjustable expansion device by displacing theactuator and the adjustable expansion device relative to the expandabletubular member in the first direction; and plastically deforming andradially expanding the expandable tubular member by moving theadjustable expansion device through the expandable tubular member in thesecond direction.
 85. The method of claim 84, wherein displacing theactuator of the apparatus in the second direction comprises: impactingthe actuator with the first end of the expandable tubular member. 86.The method of claim 84, wherein displacing the actuator and theadjustable expansion device relative to the expandable tubular member inthe first direction comprises: impacting the actuator with the secondend of the expandable tubular member.
 87. The method of claim 84,wherein moving the adjustable expansion device through the expandabletubular member comprises: pulling the adjustable expansion devicethrough the expandable tubular member.
 88. The method of claim 84,further comprising: fluidicly sealing the interface between the tubularsupport member of the apparatus and the expandable tubular member;wherein moving the adjustable expansion device through the expandabletubular member comprises: injecting a pressurized fluid into the tubularsupport member.
 89. An adjustable expansion device, comprising: aplurality of expansion segments; means for guiding the expansionsegments on a tapered body; and means for controllably displacing theexpansion segments along the tapered body.
 90. The assembly of claim 89,further comprising: means for resiliently guiding the expansion segmentson the tapered body.
 91. The assembly of claim 89, further comprising:means for interlocking the expansion segments.
 92. The assembly of claim89, further comprising: means for dividing the expansion segments intofirst and second groups of expansion segments; and means forinterleaving the first and second groups of expansion segments.
 93. Theassembly of claim 92, further comprising: means for overlapping thefirst and second groups of expansion segments.
 94. The assembly of claim92, wherein the means for controllably displacing the expansion segmentsalong the tapered body comprises: means for displacing the first andsecond interleaved groups of expansion segments in opposite directions.95. An adjustable expansion device, comprising: a plurality of expansionsegments; means for guiding the expansion segments on a multi-sidedtapered body; means for interlocking the expansion segments; and meansfor controllably displacing the expansion segments along the taperedbody.
 96. An adjustable expansion device, comprising: a plurality ofexpansion segments; means for resiliently guiding the expansion segmentson a multi-sided tapered body; means for guiding each of the expansionsegments on opposite sides in the circumferential direction; means forinterlocking the expansion segments; and means for controllablydisplacing the expansion segments along the tapered body.
 97. Anadjustable expansion device, comprising: a plurality of expansionsegments; means for dividing the expansion segments into first andsecond groups of expansion segments; means for interleaving the firstand second groups of expansion segments; means for overlapping the firstand second groups of expansion segments; means for resiliently guidingthe expansion segments on a multi-sided tapered body; means for guidingeach of the expansion segments on opposite sides in the circumferentialdirection; and means for controllably displacing the expansion segmentsalong the tapered body.
 98. An adjustable expansion device, comprising:a plurality of expansion segments; means for dividing the expansionsegments into first and second groups of expansion segments; means forinterleaving the first and second groups of expansion segments; meansfor guiding the expansion segments on a multi-sided tapered body; andmeans for controllably displacing the expansion segments along thetapered body while also relatively displacing the first and secondgroups of expansion segments in opposite directions.
 99. An apparatusfor plastically deforming and radially expanding an expandable tubularmember, comprising: a tubular support member; an adjustable expansiondevice movably coupled to the tubular support member; means foractuating the adjustable expansion device; means for locking theactuator to the tubular support member of the apparatus; means forunlocking the actuator from the tubular support member of the apparatus;means for increasing the outside diameter of the adjustable expansiondevice by moving the tubular support member relative to the actuator,the adjustable expansion device, and the expandable tubular member. 100.The apparatus of claim 99, wherein the tubular support member includesone or more lugs; wherein the actuator includes one or morecorresponding retaining slots; and wherein the means for lockingcomprises positioning the lugs into the corresponding retaining slots.101. The apparatus of claim 99, wherein the tubular support memberincludes one or more lugs; wherein the actuator includes one or morecorresponding retaining slots; and wherein the means for unlockingcomprises positioning the lugs out of engagement with correspondingretaining slots.
 102. The method of claim 99, further comprising: meansfor fluidicly sealing the interface between the tubular support memberof the apparatus and the expandable tubular member.
 103. An apparatusfor plastically deforming and radially expanding an expandable tubularmember, comprising: a tubular support member; an adjustable expansiondevice movably coupled to the tubular support member; means foractuating the adjustable expansion device; means for displacing theactuator of the apparatus in a first direction; means for applying aresilient biasing force to the adjustable expansion device when theactuator is displaced in the first direction; means for increasing theoutside diameter of the adjustable expansion device by displacing theactuator and the adjustable expansion device relative to the expandabletubular member in a second direction opposite to the first direction.104. The apparatus of claim 103, wherein the means for displacing theactuator of the apparatus in the first direction comprises: means forimpacting the actuator.
 105. The apparatus of claim 103, wherein themeans for displacing the actuator and the adjustable expansion devicerelative to the expandable tubular member in the first directioncomprises: means for impacting the actuator.